Rapidly cooling food and drinks

ABSTRACT

Systems and methods have demonstrated the capability of rapidly cooling the contents of pods containing the ingredients for food and drinks.

RELATED APPLICATIONS

This patent application is a continuation of U.S. Ser. No. 17/403,424,filed Aug. 16, 2021, which is a continuation of patent application U.S.Ser. No. 17/124,296, filed Dec. 16, 2020, now U.S. Pat. No. 11,109,610,which is a divisional of patent application U.S. Ser. No. 17/061,986,filed Oct. 2, 2020, now U.S. Pat. No. 11,033,044, which is acontinuation of patent application U.S. Ser. No. 16/824,616, filed Mar.19, 2020, and claims the benefit of provisional patent application U.S.Ser. No. 62/961,495, filed Jan. 15, 2020, all of which are herebyincorporated herein by reference in their entirety.

TECHNICAL FIELD

This disclosure relates to systems and methods for rapidly cooling foodand drinks.

BACKGROUND

Beverage brewing system have been developed that rapidly prepare singleservings of hot beverages. Some of these brewing systems rely on singleuse pods to which water is added before brewing occurs. The pods can beused to prepare hot coffees, teas, and cocoas.

Home use ice cream makers can be used to make larger batches (e.g., 1.5quarts or more) of ice cream for personal consumption. These ice creammaker appliances typically prepare the mixture by employing a hand-crankmethod or by employing an electric motor that is used, in turn, toassist in churning the ingredients within the appliance. The resultingpreparation is often chilled using a pre-cooled vessel that is insertedinto the machine. Some electric ice cream machines take 20 to 60 minutesto make a batch of ice cream and require time consuming clean up.

SUMMARY

This specification describes systems and methods for rapidly coolingfood and drinks. Some of these systems and methods can cool food anddrinks in a container inserted into a counter-top or installed machinefrom room temperature to freezing in less than two minutes. For example,the approach described in this specification has successfullydemonstrated the ability make soft-serve ice cream from room-temperaturepods in approximately 90 seconds. This approach has also been used tochill cocktails and other drinks including to produce frozen drinks.These systems and methods are based on a refrigeration cycle with lowstartup times and a pod-machine interface that is easy to use andprovides extremely efficient heat transfer.

Some of the pods described are filled with ingredients in amanufacturing line and subjected to a sterilization process (e.g.,retort, aseptic packaging, ultra-high temperature processing (UHT),ultra-heat treatment, ultra-pasteurization, or high pressure processing(HPP)). HPP is a cold pasteurization technique by which products,already sealed in its final package, are introduced into a vessel andsubjected to a high level of isostatic pressure (300-600 megapascals(MPa) (43,500-87,000 pounds per square inch (psi)) transmitted by water.The pods can be used to store ingredients including, for example, dairyproducts at room temperature for long periods of time (e.g., 9-12months) following sterilization.

Ice cream is considered a low acid food with pH levels ranging between5.0 and 8.0. The acidity of ice cream is shown in the table below inrelation to other food. The table shows a range of pH levels along ahorizontal axis ranging from high alkaline content foods on the left, tohigh acid content foods on the right. Ice cream is a low acid foodwithin the eggs and dairy food category. More specifically, a low-acidfood is a food with a finished equilibrium pH greater than 4.6 and awater activity greater than 0.85.

Food High Low High Category Alkaline Alkaline Alkaline Low Acid AcidAcid Grains, Amaranth, Rye White Rice, Cereals Lentils, Bread, WhiteSweetcorn, Whole Bread, Wild Rice, Grain Pastries, Quinoa, Bread,Biscuits, Millet, Oats, Pasta Buckwheat Brown Rice Meat Liver, Fish,Beef, Oysters, Turkey, Pork, Organ Chicken, Veal, Meat Lamb Shellfish,Canned Tuna & Sardines Eggs & Breast Soy Whole Eggs, Parmesan, DairyMilk Cheese, Milk, Camembert, Processed Soy Milk, Butter, Hard CheeseGoat Milk, Yogurt, Cheese Goat Cottage Cheese, Cheese, Buttermilk,Cream, Whey Ice Cream Nuts * Hazelnuts, Chestnuts, Pumpkin, Pecans,Peanuts, Seeds Almonds Brazils, Sesame, Cashews, Walnuts CoconutSunflower Pistachios Seeds Oils Flax Seed Corn Oil, Oil, Olive SunflowerOil Oil, Margarine

FIG. 1 is a process diagram for one approach to manufacturing ice cream.In this approach, the raw material undergoes homogenization,pasteurization, crystallization, quick freezing, packaging, and storage.

Pasteurization is a process in which food (e.g., dairy or milk) istreated with mild heat, usually to less than 100° C. (212° F.), toeliminate pathogens and extend shelf life. The process is intended todestroy or deactivate organisms and enzymes that contribute to spoilageor risk of disease, including vegetative bacteria, but not bacterialspores. Pasteurization is not sterilization and may not kill bacterialspores. Pasteurization reduces the number of organisms in food.

The shelf life of refrigerated pasteurized dairy is usually greater thanthat of milk. For example, high-temperature, short-time (HTST)pasteurized milk typically has a refrigerated shelf life of two to threeweeks, whereas ultra-pasteurized milk can last much longer, sometimestwo to three months. When ultra-heat treatment (UHT) is combined withsterile handling and container technology (such as retort or asepticpackaging as previously described), the dairy can even be storednon-refrigerated for much longer periods of time, e.g., 9-12 months.

However, during ultra-heat treatment combined with retort-based sterilehandling and container technology, pasteurized dairy can caramelize andbecome brown which can be undesirable. The highest rate of browning, ormore generally referred to as color development, can be caused by thepresence of fructose which begins to caramelize at temperatures of 230°F. Caramelization should not be confused with the Maillard reaction, inwhich reducing sugar reacts with amino acids. The process of browning,or the Maillard reaction, creates flavor and changes the color of food.Maillard reactions generally begin to occur at temperatures above 285°F. For example, caramelization temperatures of fructose can be 230° F.,galactose can be 320° F., glucose can be 320° F., lactose can be 397°F., and sucrose can be 320° F.

While the pasteurization process extends shelf life, there can also be aneed for homogenization. Homogenization is typically done either beforeor after pasteurization but before the freezing of the liquid ice creammix. Homogenization is a commonly performed for any ice cream mixcontaining fat or oil and is traditionally used in the production ofdairy products such as milk, yogurt, ice cream, and beverages such asjuice, soy milk, and peanut milk. Homogenization not only creates auniform mix, but also reduces the size of the fat droplets, resulting ina stabilized emulsion. It results in a greater viscosity and in theproduction of a more uniform color. It gives ice cream its creamytexture by breaking down large fat globules.

The process of homogenization occurs in the homogenizer, which workslike a piston pump by drawing in air and then forcing it out at a veryhigh pressure. This pressure is used to force the liquid ice creamthrough a very small tube-like opening, creating very fine fat particlesthat prevent the separation of cream. The pressure depends on the fatand solids in the liquid ice cream mix. Lower pressures can be used whenhigh fat and total solids are included in the liquid ice cream mix. If atwo stage homogenizer is used, a pressure of 2000-2500 psi on the firststage and 500-1000 psi on the second stage are satisfactory under mostconditions, however for low-fat ice creams the pressure can be higher(e.g., 2,900 psi). Two stage homogenization is preferred for ice creammix. Clumping or clustering of the fat is reduced by producing athinner, more rapidly whipped ice cream mix.

The high pressure of the homogenization process creates a more stableemulsion and smaller fat particles. The smaller the fat particles, themore surface area is obtained. This results in more fat networks thatwill stabilize more air, which in turn slows down icere-crystallization. For high-fat ice cream, the homogenization pressureis lower. Especially for an ice cream mix of more than 13% fat, it ispreferable to reduce the pressure to minimize the risk of clusterformation. In addition, this process effectively mixes all theingredients, avoids disintegration of any soft materials and preventsthe growth of harmful bacteria. Homogenization is important in the icecream production process, since it determines the reaction of the icecream mix when it is frozen, hardened and distributed. Homogenization ofthe ice cream mix gives the ice cream a smoother texture, gives the icecream greater apparent richness and palatability, give the ice creambetter air stability and increases the ice cream's resistance tomelting.

Low-acid foods packaged in hermetically sealed containers are defined aslow-acid-canned-foods (“LACF”) and are regulated by Title 21, Code ofFederal Regulations (21 CFR) part 113. A hermetically sealed containeris a container that is designed and intended to be secure against theentry of microorganisms and thereby to maintain the commercial sterilityof its contents after processing. Low-acid-canned-foods are defined bybeing (i) shelf stable, (ii) heat-treated, (iii) having a pH of >4.6,and (iv) having a water activity of 0.85.

Once packaged, the low-acid-canned-food is sterilized. The method ofsterilization is a thermal based process, or the application of highheat to the product. The high temperatures required in a sterilizationprocess destroys pathogenic organisms that may be present in/on thecontainer and/or food product, and is well above the boiling point ofwater at normal atmospheric pressure. Sterilization kills or deactivatesliving organism in the food product. Thermal processing/sterilization ofshelf stable, low acid foods is usually performed at temperatures at orabove about 250° F. The higher the temperature, the shorter the time theproduct needs to be exposed to heat.

There are two primary methods for sterilizing low-acid-canned-foods suchas ice cream. The first method is a retort process, sometimes alsocalled an autoclave or sterilizer, which is a pressure vessel used inthe food manufacturing industry to sterilize or “commercially sterilize”food after it has been placed into its container and the container hasbeen hermetically sealed. A report process or “retort” machine can bestatic or agitating style machines. Agitating style retort machines aretypically used for convective (e.g., “flowable liquid”) type products,such as liquid ice cream, that benefits from some product movement(e.g., “stirring”) in the container during the process. These benefitscan either be from a process stand-point (e.g., to improve the rate ofheat transfer into/out of the container), and/or from a product qualitystand-point (e.g., to shorten the exposure time to heat). Agitatingstyle retorts can utilize various methods of agitation depending on theorientation of the product container. Vertically oriented containers,such as cans, are typically agitated in a rotary fashion, either axiallyor end-over-end, but horizontal agitation can also be used.

The second process of sterilizing low-acid-canned-foods is asepticprocessing which is a processing technique where commercially thermallysterilized liquid products (typically foods such as liquid ice cream)are packaged into previously sterilized containers under sterileconditions to produce shelf-stable products that do not needrefrigeration. Aseptic processing includes aseptic hermetical sealing inan atmosphere free of microorganisms. The regulations of 21 CFR 113include guidance on times and temperatures for the sterilizationprocess.

The best ice creams have a smooth and creamy texture. This creamytexture, primarily associated with a high fat content, is alsodetermined by the average size of the ice crystals. Ice crystal size isgoverned by the mix formulation, as well as by factors relating to thefreezing process; residence time; the evaporation temperature of therefrigerant fluid; dasher speed; and draw temperature. Each of thesefactors is described in detail below. Although discussed with respect toice cream, the relationship between ice crystals and smoothness is alsorelevant to other frozen foods and drinks.

FIG. 2A shows a typical relationship between smoothness and ice crystalsize. In FIG. 2A, ice crystal size increases from left to right alongthe horizontal axis while the smoothness increases from bottom to topalong the vertical axis. Typical values are shown with an approximatelinear trend line through the data. The data and trend indicates thatdecreasing ice crystal size (down to micrometer size) is directlycorrelated with increasing smoothness of the ice cream. Ice crystal sizecan be measured in various ways such as using a light microscope.Typically a quantity of ice cream is analyzed and an average ice crystalsize is measured by the light microscope. It is possible to havevariations in ice crystal size. Smooth and creamy ice cream requires themajority of ice crystals to be small, under 50 μm in size, andpreferably 10-20 μm in size. If many crystals are larger than this, theice cream will be perceived as being coarse or icy.

Ice crystals in ice cream range in size from about 1 to over 150 μm indiameter, with an average size of about 25 μm. Small ice crystals,around 10 to 20 μm in size, give ice cream its smooth and creamytexture, whereas larger ice crystals, for example ice crystals greaterthan 50 μm, impart a grainy texture.

The growth of the ice crystals can be controlled using stabilizers.Stabilizers are typically used to increase the melt resistance and shelflife of ice cream. Examples of stabilizers are guar gum, carob bean gumand cellulose gum and limit the growth of ice crystals by limiting themobility of water in the unfrozen ice cream mix. Stabilizers also limitice crystal growth by reducing ripening that occurs during early stagesof hardening and during storage and distribution of the ice cream mix(e.g., when the ice cream mix is exposed to relatively high temperatures(e.g. +10 to +18 F)). In these temperature ranges, a degree of freezeconcentration is low, producing relatively low viscosity in the unfrozenportion. Low viscosity allows water to migrate from small to large icecrystals, which increases the average ice crystal size of the ice cream.Stabilizer act to limit this ice crystal growth by increasing theviscosity of the ice cream mix. Stabilizers limit water mobility byreducing a ripening effect at a freeze concentration. Stabilizers limitthe size of air bubbles which grown through a process of disproportion.

The rheological effects of stabilizers are important in stabilizingproperties of the finished ice cream related to the mobility of water inthe unfrozen system. For example, high viscosity ice cream limits thetemperature at which ice cream can be withdrawn and handled from thebarrel of the ice cream freezer. When this happens, the amount of waterfrozen in the freezer is reduced. This has an undesirable effect on theresistance of the ice cream to heat shock. Low-viscosity stabilizershave not traditionally been used in ice cream because of an assumed lackof influence on water mobility.

At a point referred to as the “break point,” a degree of concentrationcan cause the stabilizer and, possibly, other water-soluble compounds,to interact with each other, sometimes irreversibly, thus markedlyincreasing the effect on water mobility. This can be combined with anextreme freeze concentration that occurs at low frozen storagetemperatures to produce other interactions between individualwater-soluble compounds.

In addition to stabilizers, emulsifiers are traditionally added to anice cream mix. Emulsifiers migrate to the interface between the fat andthe water of the ice cream mix. Emulsifiers attach themselves to thesurface of the fat globules and cause the protein molecules to displaceEmulsifiers are used to improve the melting properties during shippingand storage. Examples of emulsifiers are mono-diglycerides (E471),lactic acid esters (E472b), propylene glycol esters (E477) and blends ofthese.

Emulsifiers are used in ice cream because they contribute to smooth andcreamy texture by promoting fat destabilization. Fat destabilizationrefers to the process of clustering and clumping (known as partialcoalescence) of the fat in an ice cream mix when it is churned in amachine. Because it is the proteins that stabilize the fat emulsion inan ice cream mix, emulsifiers are added to ice cream to reduce thestability of this emulsion and encourage some of the fat globules tocome together, or partially coalesce. When a mix is churned in an icecream machine, air bubbles that are beaten into the mix are stabilizedby this partially coalesced fat, giving a smooth texture to the icecream. Traditionally, if emulsifiers were not added, the air bubbleswould not be properly stabilized and the ice cream would not have thesame smooth texture.

Egg yolks are used as both a stabilizer, that thickens the mixture, andas an emulsifier, which encourages partial coalescence. To make use ofthe emulsifying properties of egg yolks, approximately 0.5 to 1% of themixture should be egg yolk. To make use the stabilizing (thickening)properties as well, the proportion of egg yolk is traditionallyincreased to 3-4%. However, some frozen custard style ice creams caninclude over 8% of egg yolk.

Egg yolks include Lecithin which helps to make them good emulsifiers. Infact, egg lecithin has emulsification and lubricant properties, and is asurfactant. However, Lecithin need not only be extracted from egg yolk.Lecithin can be extracted from plant-based sources such as soybeans,sunflowers and rapeseed. Plant-based Lecithin can emulsify just as wellas egg yolks without egg flavor and extra fat.

Many store-bought ice creams include stabilizers and emulsifiers to helpkeep the ice crystals from growing by improving the melting propertiesduring shipping and storage and by increasing the shelf life of icecream. An example is Ben & Jerry's Cinnamon Buns ice cream whichincludes: cream, skim milk, water, liquid sugar, sugar, dried canesyrup, wheat flour, corn syrup, egg yolks, brown sugar, soybean oil,butter, coconut oil, molasses, salt, cinnamon, soy lecithin, sodiumbicarbonate, spice, vanilla extract, guar gum, and carrageenan. In thisexample, the stabilizers include guar gum and the emulsifiers includeegg yolks, soybean oil, soy lecithin, carageenan.

As previously described, ice crystal size is a factor in the developmentof smooth and creamy ice cream. Creamy ice cream requires the majorityof ice crystals to be small, preferably under 50 μm in size. If manycrystals are larger than this, the ice cream will be perceived as beingcoarse.

Ice cream is frozen in two stages: dynamic and static freezing. Dynamicfreezing is a dynamic process where the mix is frozen in an ice creammachine while being agitated to incorporate air, destabilize the fat,and form ice crystals. The ice cream mix enters the ice cream machine ata temperature slightly above its freezing point, i.e., the temperaturewhere the water in the mix begins to freeze. The ice cream machine coolsthe mix and brings it below the freezing point of the mix. At thispoint, a layer of ice freezes to the walls of the ice cream machinewhich causes rapid nucleation where small ice crystals begin to form.Upon exiting the ice cream machine, the ice cream, at about −5° C. to−6° C. (23 to 21.2° F.) exits with a consistency similar to soft-serveice cream.

The ice cream then undergoes static freezing where it is hardened in afreezer without agitation until the core of the ice cream reaches aspecified temperature, usually −18° C. (−0.4° F.). New ice crystals areformed during static freezing but the existing small crystals begin togrow in size until the temperature decreases to −18° C. (0.4° F.), orideally −25° C. to −30° C. (−9.4 to −20.2° F.), to halt this growth. Itis advantageous to cool the ice cream as quickly as possible during thisprocess to limit the growth of the ice crystals.

During static freezing, ice crystals typically grow by about 30% to 40%to an average size of about 25 to 45 μm. A mean ice crystal size ofabout 50 μm is considered an average point where consumers start tonotice a coarse texture. During static freezing ice crystals can oftengrow to over 100 μm. FIG. 2B shows an image of typical ice crystalsduring this process. The ice crystals in the image of FIG. 2B are ofvarious shapes and sizes but some ice crystals are over 100 μm indiameter.

However, the ice cream described in this specification does not requirestatic freezing because the ice cream is not stored. The ice cream isserved ready for consumption. By eliminating the static freezing step,growth of ice crystals (e.g., ice crystals typically grow by about 30%to 40%) during the static freezing process is eliminated.

The dynamic freezing stage is an important step in creating ice creambecause this is the stage in which crystallization of the ice creamoccurs. During dynamic freezing, the ice cream mix is added to the icecream machine at between 0° C. and 4° C. (32° F. and 39.2° F.). As therefrigerant absorbs the heat in the mix, a layer of ice freezes to thewall of the cold barrel wall causing rapid nucleation, that is, thebirth of small ice crystals.

To produce small ice crystals during a dynamic freezing process, a highrate of nucleation, minimal growth, and minimal recrystallization aredesired. Colder refrigerant temperatures and slower dasher speeds canpromote higher rates of nucleation. Shorter residence times, lowerdasher speeds, and lower draw temperatures can to minimize growth andrecrystallization.

FIG. 2C shows a process of a rotating dasher also called a mixer,impeller, blade, scraper, or paddle, where the rotating dasher is usedto scrape the ice crystals formed at the cold barrel wall 22. The designand rotation of the rotating dasher directs the ice crystals formed atthe cold barrel wall 22 to the center of the barrel (the bulk region)where the temperature is warmer and ice crystals grow in size. Thiscauses some crystals to melt and some to undergo recrystallization.

For smooth and creamy ice cream, it's desirable to have a high rate ofnucleation so as to form as many small ice crystals as possible. Themore ice crystals that are formed during dynamic freezing, the more icecrystals will be preserved during static freezing, resulting in asmaller average crystal size and smoother texture. Fewer crystals formedduring dynamic freezing, or a lower rate of nucleation, can result incoarse texture as these crystals eventually grow to a significantlylarger size.

Crystallization during dynamic freezing can be divided into two zones:the wall region, where the temperature at the barrel wall is cold enoughfor nucleation to occur, and the bulk region, where warmer temperaturesin the center of the barrel mean that ice crystal growth andrecrystallization, also called ripening or coarsening, predominate. Thegreater the extent of growth and recrystallization in the bulk region,the larger the ice crystals will be. Crystallization during ice creamfreezing may be dominated by recrystallization and growth and that thesemechanisms can be more important than nucleation in determining thefinal crystal population. Minimizing growth and recrystallization is,therefore, of paramount importance.

Residence time (the length of time ice cream spends in the ice creammachine) can have a significant effect on the final ice crystal sizedistribution, with shorter residence times producing ice creams withsmaller ice crystals due to a decline in recrystallization. A longerresidence time means that ice cream is slower to reach its drawtemperature (the temperature at which ice cream is extracted from theice cream machine) of around −5° C. to −6° C. (23° F. to 21.2° F.),which means that it spends more time in the bulk zone where warmertemperatures cause rapid recrystallization. It can be advantageous tominimize the residence time of the ice cream in the ice cream machine byreaching the draw temperature as quickly as possible. This can beachieved by mixing and cooling as quickly as possible.

FIG. 2D illustrates the dependence of draw temperature on ice crystaldistribution of ice cream made with 28 D.E. (dextrose equivalent) cornsyrup, a dasher speed of 500 RPM (revolutions per minute), and a flowrate of 34 l/h (liters per hour). The average diameter of the icecrystals increases from left to right along the horizontal axis whilethe percentage of the ice cream that contains this average diameter ofice crystal size is shown increasing from bottom to top on the verticalaxis. As draw temperature decreases, the average diameter of the icecrystals in the ice cream also decreases.

For example, one can measure a recrystallization rate at −5° C. (23° F.)of 42 μm/day. At this rate, an ice crystal size increase of around 8 μmwould be expected over a 10 minute period. This can match an increase inice crystal size at a slightly different temperature of −4° C. (24.8°F.). The longer the ice cream remains within the ice cream machine attemperatures where recrystallization occurs very rapidly, the greaterthe extent of recrystallization, and the larger the ice crystals.

Investigating the effect of draw temperature, dasher speed, andresidence time on ice crystal size indicates that these aspects canimpact the final crystal size distribution.

Primary refrigerants (i.e., liquid ammonia or Freon) are used in icecream machines to provide temperatures in the range of −23° C. to −29°C. (−9.4° F. to −20.2° F.), with temperatures at the barrel wall being afew degrees warmer. Decreasing the refrigerant temperature promotesrapid heat removal at the barrel wall. Rapid heat removal allows forfaster ice nucleation rates, which results in smaller ice crystals dueto the higher number of small ice crystals.

For ice crystal size in sorbet, low refrigerant temperatures (up to−19.9° C. (−3.82° F.)) can lead to lower draw temperatures and asignificant reduction in the ice crystal chord length. This is due tofaster freezing, which causes faster formation of more ice crystals.Reductions in ice crystal length as a function of a decreasingevaporation temperature can be observed.

The barrel wall temperature has a direct effect on the cooling rate (therate at which heat is removed from the ice cream mix), and therefore onresidence time. Lower wall temperatures can lower the bulk temperatureof the ice cream faster, reducing residence time and improving the icecrystal size distribution.

During dynamic freezing, heat input from the rotating scraper blades,due to friction at the barrel wall and viscous dissipation, can besignificant, accounting for as much as 50% of the total heat removed bythe refrigerant. Increasing the dasher speed can cause an increase inthe ice cream temperature, resulting in a significant increase in theaverage ice crystal size. This likely occurs because the extrafrictional heat generated by the blades melts many of the smallestcrystals, resulting in a lower nucleation rate and the enhancement ofrecrystallization. For this reason, dasher speeds are usually limited to100-200 RPM. The large amount of frictional heat inputted by higherdasher speeds will also slow the freezing process, resulting in longerresidence times.

Sometimes the motion of the rotating blade is not enough to cause thefat globules in the ice cream mix to clump together to partiallycoalesce which is important for developing and maintaining small airbubbles in the ice cream. Emulsifiers in the ice cream mix aid in theprocess of de-stabilizing the fat globules so they can clump together.

However, the ice cream described in this specification does not requireemulsifiers because the quickly rotating dasher and the quick freezingprocess capability of the machines described in this specification aresufficient in developing a smooth and creamy ice cream quickly.

Additionally, the ice cream described in this specification does notrequire stabilizers because the ice cream does not need to be stored inthe frozen state, so there is no need to increase the melt resistanceand shelf life of ice cream using stabilizers.

Developing ice cream void of emulsifiers and stabilizers is an advantageof the ice cream described in this specification, even though a smallamount of emulsifiers and stabilizers can be added in some cases. An icecream void of emulsifiers and stabilizers, and only including milk,cream, and sugar, is considered a “clean label” ice cream and is anadvantage of the ice cream mix described in this specification. A cleanlabel refers to food products that have fewer and simpler ingredients,where the ingredients are from natural sources.

FIG. 2D illustrates that draw temperature can have a significantinfluence on mean ice crystal size, with lower drawing temperaturesgenerally resulting in smaller ice crystals. Factors influencing drawtemperature include the refrigerant temperature, heat transfer,residence time, and overrun. Ice crystals can become larger at drawtemperatures from −3 to −6° C. (26.6° F. to 21.2° F.). When the drawtemperatures are colder than −6° C. (21.2° F.), the mean ice crystalsize decreases. The smaller ice crystal sizes can be attributed to thelower refrigerant temperatures necessary to obtain lower drawtemperatures.

An increase in dasher speed can lead to an increase in drawtemperatures. For example, when dasher speed is increased from 600 to900 rpm, a 1° C. (1.8° F.) increase in draw temperature, due tofrictional energy transmitted to the ice cream, can be observed.Conversely, an increase in dasher speed can also lead to an increase inthe heat transfer at the barrel wall, producing lower draw temperatures.As previously noted, dasher speeds are usually limited to 100-200 RPM.

However, the ice cream machines and processes described in thisspecification use a dasher speed that is varied during freezing from 100to 1200 RPM to reduce freeze times and reduce ice crystal size to below, sometimes smaller than 30 μm with an average crystal size of under20 μm (19.1 μm) and having no ice crystals above 40 μm. These propertiescan be similar to store-bought ice cream that have gone thru a staticfreezing process (i.e., a hard pack process).

Lower draw temperatures can also be attained through longer residencetimes. As previously noted, however, longer residence times mean thatice cream spends more time at temperatures where rapid growth andrecrystallization occur, resulting in larger ice crystals. The dynamicfreezing step can account for competing phenomena as shorter residencetimes are needed to produce small ice crystals, but longer residencetimes give a lower draw temperature.

The drawing temperature has been observed to have an effect on mean icecrystal diameter, followed by the mix flow rate (which determines theaverage residence time), overrun, and dasher speed. When the drawingtemperature is warmer than −5° C. (23° F.), mean ice crystal diameter isstrongly dependent on the drawing temperature, with larger mean icecrystals reported at warmer draw temperatures. When the drawingtemperature is colder than −5° C. (23° F.), however, not only the drawtemperature, but also the overrun (the amount of air whipped into icecream), influenced the mean ice crystal diameter.

Differences in the mean ice crystal diameter may be insignificant whenthe drawing temperatures are between −5° C. and −6.5° C. (23° F. and20.3° F.) and the overrun is below 70%. At higher overruns, the mean icecrystal diameter is often smaller. Tiny ice crystals can be formed whenboth the overrun and dasher speed are raised. However, as previouslynoted, increasing the dasher speed can cause an elevation in producttemperature, which leads to the melting of small crystals and enhancedrecrystallization.

Some ice cream machines rotate the mixing paddle at a constant RPMduring the freezing and dispensing cycle. Additionally, the rotationalspeed of the mixing paddle is typically kept low, because as previouslydescribed, heat input from the rotating scraper blades can besignificant. For this reason, dasher speeds are usually limited to100-200 RPM. Furthermore, the large amount of frictional heat inputtedby higher dasher speeds is known to slow the freezing process, resultingin longer residence times.

Cooling is used to indicate the transfer of thermal energy to reduce thetemperature, for example, of ingredients contained in a pod. In somecases, cooling indicates the transfer of thermal energy to reduce thetemperature, for example, of ingredients contained in a pod to belowfreezing.

The systems and methods described in this specification describe amachine with a mixing paddle that rotates slower in the beginning of anice cream making process when the ice cream mix is liquid. In thisstate, increasing the amount of time that the liquid touches an innerdiameter of the pod's wall is helpful for changing the ice cream mixfrom a liquid to ice. As the pod's wall becomes colder, using anevaporator of the ice cream machine, the rotational speed of the mixingpaddle is increased to verify that the ice crystals are kept to a smallsize, preferably under 30 μm.

The action of speeding up the mixing paddle as the ice cream mix becomesincreasingly more viscous can be counterintuitive. This iscounterintuitive because the rotational speed of the mixing paddle islimited by a driving torque of the motor and increasing the rotationalspeed of the mixing paddle when the ice cream mix becomes more viscousincreases the torque required by the motor. This requires more power bythe motor. Furthermore, rotating the mixing paddle faster may damage icecream machines that are not designed for such speeds.

However, by increasing the rotational speed of the mixing paddle in ourmachine, the machine is able to suck air into the pod. The process ofsucking air into the pod in combination with the rotation of the mixingpaddle helps churn the air into the frozen confection, creating airbubbles in the frozen confection. This process preferably creates atleast a 30% overrun.

A clean label ice cream mix packaged in a sterilized container or poddescribed in this specification can advantageously provide (i) naturalingredients, (ii) storage at room temperatures opposed to need to berefrigerated or frozen, and (iii) long shelf-life at room temperatures,typically 6-9 months.

An ice cream machine for a pod of the clean label ice cream mixdescribed in this specification can advantageously provide (i) an icecream with very small ice crystals, often less than 40 μm in diameter onaverage (and sometimes less than 30 μm in diameter on average), whichgive the ice cream a smoother texture, and (ii) delivery of ice creamfrom room temperature to dispensing in less than 3 minutes.

The ice creams produced using the machines described in thisspecification have a much smaller ice crystal size on average and a muchtighter standard deviation of ice crystal size than their store-boughtcounterparts. This is important because the ice cream machines describedin this specification produce smoother ice cream that does not requirerefrigeration or freezing prior to production for consumption. The icecreams used in these machines do not need to include non-naturalingredients such as emulsifiers or stabilizers in the ice cream. The icecream ingredients used with these machines can be “clean-label” andcontain simply milk, cream, sugar, and powdered milk and can be storedat room-temperature for up to 9 months in a sterilized pod. The pods cansimply be inserted into the machines described in this specification anda frozen ice cream is dispensed within minutes for a consumer to enjoy.These ice cream machines are designed to provide helpful interactionsbetween the increasing rotational speed of mixing paddle, the design ofthe pod, and the rapid cooling properties of the evaporator andrefrigeration system, come to together to make this possible.

Some devices and methods for providing a single serving of a frozeninclude: filling low acid liquid ingredients having an pH level of 4.0or great into a pod; inserting the pod into a recess of a machine forproviding the single serving of the frozen confection; contacting asidewall of the pod against a sidewall of the recess; cooling the recesswith a refrigeration system of the machine, pulling heat out of the podwhile connecting a motor of the machine to a mixing paddle inside thepod; and moving the mixing paddle inside the pod at an increase in RPMover the freezing cycle to remove built up of ice from the innerdiameter of the pod and dispersing the ice into the center of the podwhile mechanically churning the ice into the balance of the fluid andsimultaneously moving the warmer fluid ingredients from the center ofthe pod to the cooler inner dimeter of the pod in contact with therecess of the machine to facilitate quicker heat transfer.

Some devices and methods for providing a single serving of a frozenconfection made in less than five minutes having a temperature between17 degrees and 26 degrees Fahrenheit with a majority of its ice crystalssmaller than 50 μm include: filling low acid liquid ingredients havingan pH level of 4.0 or great into a pod; inserting the pod into a recessof a machine for providing the single serving of the frozen confection;contacting a sidewall of the pod against a sidewall of the recess;cooling the recess with a refrigeration system of the machine, pullingheat out of the pod while connecting a motor of the machine to a mixingpaddle inside the pod; and moving the mixing paddle inside the pod toremove built up of ice from the inner diameter of the pod and dispersingthe ice into the center of the pod while mechanically churning the iceinto the balance of the fluid and simultaneously moving the warmer fluidingredients from the center of the pod to the cooler inner dimeter ofthe pod in contact with the recess of the machine to facilitate quickerheat transfer.

Embodiments of these machines can include one or more of the followingfeatures.

In some embodiments, the mixing paddle rotates at least 50 RPM in thebeginning of the refrigeration cycle and increases to at least twicethat during the course of the refrigeration cycle.

In some embodiments, the dispensing of the frozen confection is donewhen its temperature is between 17-26 degrees Fahrenheit and the mixingpaddle is rotating over 100 RPM.

In some embodiments, the filling of the low acid liquid ingredientshaving an pH level of 4.0 or great is done before the pod is insertedinto the recess of the machine for providing the single serving of thefrozen confection.

In some embodiments, the frozen confection is a low acid food includingup to approximately 0.5% emulsifiers and/or up to approximately 0.5%stabilizers. In some cases, the stabilizers can be thickeners such assodium carboxymethyl cellulose (cellulose gun), guar gum, locust beangum, sodium alginate, propylene glycol alginate, xanthan, carrageenan,modified starches, microcrystalline cellulose (cellulose gel), gelatin,calcium sulfate, propylene glycol monostearate or other monoesters, andothers. In some cases, the emulsifiers can be mono- and diglycerides,distilled monoglycerides (saturated or unsaturated), polyoxyethylenesorbitan monostearate(60) or monooleate (80), and others. In some cases,the ice cream mix formulation can have minimal or no stabilizers.

In some embodiments, the pod may be a multi-use, reusable pod.

In some embodiments, the pod has completed a retort sterilizationprocess to make its low acid ingredients shelf-stable at roomtemperature.

In some embodiments, the pod has been aseptically filled and sealed tomake its low acid ingredients shelf-stable at room temperature.

In some embodiments, the mixing paddle is part of the machine.

In some embodiments, the pod is an aluminum beverage can.

In some embodiments, the pod is frustoconical.

In some embodiments, the frozen confection has an average ice crystalsize of less than 30 μm.

In some embodiments, the ice cream formulation is considered a “cleanlabel” without the use of stabilizing gums.

In some embodiments, the mixing paddle is helical and the rotation ofthe paddle removes the built up of ice from the inner diameter of thepod and drives the frozen confection downward.

In some embodiments, the mixing paddle is helical and the rotation ofthe paddle removes the built up of ice from the inner diameter of thepod and moves the ice to the center of the pod while pushing the warmerfluid from the center of the pod to the cooler inner diameter of thepod.

In some embodiments, the mixing paddle is rotated and the rotationalspeed of the paddles are varied in response to the changing viscosity ofthe frozen confection in pod.

In some embodiments, dispensing the frozen confection from the pod intoan edible cone or a collecting container while the pod is in the recessof the machine without the frozen confection coming into contact withanother object.

In some embodiments, the mixing paddle forces the frozen confection outof pod.

In some embodiments, the recess of the machine can have an open andclosed position and the cooling of the pod occurs when the recess is inthe closed position.

In some embodiments, the refrigeration system cools the pod with acompressor and uses a two-phase refrigerant fluid, for example R22,R134A, R-600a or R290. In some cases, the compressor is a reciprocatingcompressor. In some cases, the compressor is a rotary compressor. Insome cases, the compressor is a Direct Current (DC) compressor. In somecases, the DC compressor has a variable motor speed to allow forincreased displacement towards the begging of the refrigeration coolingcycle, the first 45 seconds for example of cooling the pod and slow downthe motor speed towards the end of the cooling cycle of the pod whenmost of the refrigerated fluid has been evaporated. In some cases, theDC compressor has a variable motor speed that is adjusted depending onthe load on the machine's refrigeration cycle.

The systems and methods describe in this specification can providevarious advantages.

Some of these features of these systems and methods allow the dasherspeed to be varied or increased during freezing of the ice cream in thesingle serve pod. Mixing paddle rotational speed could vary from 50 to1200 RPM to reduce freeze times and reduce ice crystal size to be low,about 50 μm or smaller.

Some of these systems use a low temperature refrigerant such as R290 orR-600A should be used at temperatures (−7° C. to −19.9° C.) toeffectively achieve draw temperatures to achieve ice crystals less than50 μm for the majority of the single serve batch.

Some of these systems use liquid ice cream mix that is shelf-stable for9-12 months. This is achieved by performing a retort process wherehermetically sealed pods of liquid ice cream mix is heated to 250° F.for at least 5 minutes. By using unpasteurized dairy in our pods andperforming a retort process on the pod before use, the dairy inside thepod is only getting pasteurized once. This is in contrast to the typicalpasteurization process illustrated in FIG. 1 where the dairy is usuallypasteurized before leaving the dairy factory which means it ispasteurized twice, e.g., once at the dairy factory and once in ourretort process.

Some of these systems and processes use a retort process that retorts at250° F. even though retorting at higher temperatures is generallypreferred because it would allow the pasteurization process to completein less time. Completing a retort at 250° F. can limit the effect ofbrowning when we remove fructose from the ice cream mix formulation.

Some of these features of these systems and methods lead to compactmachines. For example, machines with sliding lid assemblies are morecompact than systems with pop-up lid assemblies. This approach canfacilitate placement of machines in home use on kitchen countertopsunderneath kitchen cupboards which are often 18″ distance from thecountertops. Machines with a quickly mixing paddle rotating at upwardsof 100 to 1,500 RPM can cause a suction effect by drawing air into thecontainer. Such a process does not need to use a separate air supply andmakes the overall system more compact than systems which inject air intoice cream being formed.

Some of these systems and methods provide improved mixing. For example,systems with a mixing paddle that has off center holes can create amixing effect that stirs the contents of a container better than asymmetric mixing paddle.

Some of these systems are easy to use. For example, some machines do notrequire a user to align pods (e.g., cans) being inserting into themachines. In another example, machines that do not require a user tolower a lid manually to apply force to insert a plunger into a containerare more accessible to users without limited strength. Machines thatprovide this functionality without an additional motor tend to be morecompact and simpler than machines that include a specific motor toprovide this functionality.

Some of these systems and methods provide operational advantages. Forexample, machines with a refrigeration system that has a heater and/or ahot gas bypass can reach steady state quickly. This approach can improveperformance and reduce wait times. Some systems include mixing motorsthat does not reverse direction and that continue to rotate thedriveshaft through a mixing, shearing, and a dispensing cycle. Thisapproach appears to reduce the likelihood of the mixing motor stallingas viscosity of the contents of the pod increase with cooling.

Some systems include a shearing cap designed to shear a protrusion of acontainer. A machine with such a shearing cap can more securely grip apod during use so the pod is less likely to slip. This can improveperformance of the machine.

Some machines offer vending-type dispensing capability to allow them toaccept payment for ice cream, provide a variety of ice creamflavors/options, and to make them easily used in commercialenvironments.

For ease of description, terms such as “upward”, “downward” “left” and“right” are relative to the orientation of system components in thefigures rather than implying an absolute direction. For example,movement of a driveshaft described as vertically upwards or downwardsrelative to the orientation of the illustrated system. However, thetranslational motion of such a driveshaft depends on the orientation ofthe system and is not necessarily vertical.

The details of one or more embodiments of these systems and methods areset forth in the accompanying drawings and the description below. Otherfeatures, objects, and advantages of these systems and methods will beapparent from the description and drawings, and from the claims.

DESCRIPTION OF FIGURES

FIG. 1 is a process diagram for an approach to manufacturing ice cream.

FIGS. 2A-2D illustrate ice crystals in ice cream related to smoothness,churning, and draw temperature.

FIG. 3A is a perspective view of a machine for rapidly cooling food anddrinks. FIG. 3B shows the machine without its housing. FIG. 3C is aperspective view of a portion of the machine of FIG. 3A.

FIG. 4A is perspective view of the machine of FIG. 3A with the cover ofthe pod-machine interface illustrated as being transparent to allow amore detailed view of the evaporator to be seen. FIG. 4B is a top viewof a portion of the machine without the housing and the pod-machineinterface without the lid. FIGS. 4C and 4D are, respectively, aperspective view and a side view of the evaporator.

FIGS. 5A-5F show components of a pod-machine interface that are operableto open and close pods in the evaporator to dispense the food or drinkbeing produced.

FIG. 6 is a schematic of a refrigeration system.

FIGS. 7A and 7B are views of a prototype of a condenser.

FIG. 8A is a side view of a pod. FIG. 8B is a schematic side view of thepod and a mixing paddle disposed in the pod.

FIGS. 9A and 9B are perspective views of a pod and an associateddriveshaft. FIG. 9C is a cross-sectional view of a portion of the podwith the driveshaft 126 engaged with a mixing paddle in the pod.

FIG. 10A-10D shows a first end of a pod with its cap spaced apart fromits base for ease of viewing.

FIGS. 11A-11G illustrate rotation of a cap around the first end of thepod to open an aperture extending through the base.

FIG. 12 is an enlarged schematic side view of a pod.

FIGS. 13A-13D are views of a can for a pod with seamed ends.

FIG. 14A is a photo of a retort machine. FIG. 14B is a photo of retortsterilization chambers inside a retort machine.

FIG. 15 is a flow chart of a method for operating a machine forproducing cooled food or drinks.

FIG. 16A-16C is a detailed flow chart of a method for operating amachine for producing cooled food or drinks.

FIGS. 17A-17D are perspective views of a machine for producing cooledfood or drinks.

FIGS. 18A and 18B are partial cross-sectional views of the machine ofFIGS. 17A-17D.

FIG. 19 is a partially cutaway perspective view of a driveshaft.

FIG. 20 is a perspective view of a dispenser.

FIGS. 21A-21C are schematic views that illustrate a wedge systemassociated with the pod-machine interface.

FIGS. 22A-22C are schematic views of a driveshaft with a barbed head anda matching recess on a mixing paddle.

FIG. 23 shows a perspective view of a machine with a handle connected toa pinion.

FIGS. 24A-24E show perspective and cross sectional views of a machinewith a handle that rotates on the same axis as a lid of the machine.

FIGS. 25A-25C show a portion of a machine with a spring-loaded handlethat rotates on the same axis as a lid of the machine.

FIGS. 26A-26C are perspective views of a machine for rapidly coolingfood and drinks. FIG. 26B is the machine with the top cover removed.

FIGS. 27A-27B are perspective views of the machine of FIGS. 26A-26C withinternal details shown.

FIGS. 28A-28D are perspective and cross-sectional views of a machinewith an automatic plunger in a retracted position (FIGS. 28A and 28B)and in an engaged position (FIGS. 28C and 28D).

FIGS. 29A-29D are partial perspective and plan views of a machine with aself-driven plunger in a retracted position (FIGS. 29A and 29B) and inan engaged position (FIGS. 29C and 29D).

FIG. 30 is a partial cross-sectional view of a machine with aself-driven plunger as it moves from an engaged position to a retractedposition.

FIG. 31 is view of the internal components of a machine with anevaporator with an attached motor.

FIGS. 32A and 32B are perspective views an evaporator with an attachedmotor.

FIGS. 33A-33B are schematics of a refrigeration system.

FIGS. 34A-34D are perspective and plan views of a mixing paddle.

FIGS. 35A-35C illustrate the engagement of a mixing paddle with a pod.

FIGS. 36A-36B illustrate a polymer liner of a pod.

FIGS. 37A-37B illustrate a grommet on a driveshaft. FIGS. 37C-37D areviews of grommets.

FIGS. 38A-38D are perspective views of a mixing paddle with dog-earsdisposed inside a pod (FIG. 38A), alone (FIG. 38B), and with a connectorattached (FIGS. 38C and 38D).

FIG. 39A is a perspective view of mixing paddle using a sealedconnection to a pod. FIG. 39B is a perspective view of the exterior ofthe pod shown in FIG. 39A.

FIG. 40A is a plan view of a mixing paddle using an alternate sealedconnection to a pod. FIG. 40B is a perspective view of the mixing paddleshowing a portion of the sealed connection shown in FIG. 40A. FIG. 40Cis a perspective view of the mixing paddle and the portion of the sealshown in FIG. 40B.

FIG. 41A is a perspective view of mixing paddle using an alternatesealed connection to a pod. FIG. 41B is the seal shown in FIG. 41A. FIG.41C is the coupling shown in FIG. 41A. FIG. 41D is a plan view of themixing paddle and the alternate sealed connection shown in FIG. 41A.FIG. 41E is a perspective view of the mixing paddle and the alternatesealed connection shown in FIG. 41A with the pod hidden. FIG. 41F is aplan view of the mixing paddle and the alternate sealed connection shownin FIG. 41A with the pod hidden.

FIGS. 42A-42D are perspective and plan views of a mixing paddle using analternate sealed connection to a pod.

FIGS. 43A-43C are perspective views of a mixing paddle with eccentricwindows.

FIGS. 44A-44B are perspective views of a cam system to engage a pod.

FIGS. 45A-45E are perspective views the cam system engaging a pod.

FIG. 46 illustrate a machine with a cam system engaging a pod.

FIGS. 47A-47B illustrate a cap for a pod.

FIGS. 48A-48C are schematics of a vending machine including a machinefor producing cooled food or drinks.

FIG. 49 are ice crystal size analysis results for ice cream.

FIGS. 50A-50E are images representing an ice crystal size analysis forvarious ice creams.

FIGS. 51A-51E are histograms representing the ice crystal size analysisfor the various ice creams shown in FIGS. 50A-50E.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This specification describes systems and methods for rapidly coolingfood and drinks. Some of these systems and methods use a counter-top orinstalled machine to cool food and drinks in a container from roomtemperature to freezing in less than three minutes. For example, theapproach described in this specification has successfully demonstratedthe ability make soft-serve ice cream, frozen coffees, frozen smoothies,and frozen cocktails, from room temperature pods in approximately 90seconds. This approach can also be used to chill cocktails, createfrozen smoothies, frozen protein and other functional beverage shakes(e.g., collagen-based, energy, plant-based, non-dairy, and CBD shakes),frozen coffee drinks and chilled coffee drinks with and without nitrogenin them, create hard ice cream, create milk shakes, create frozen yogurtand chilled probiotic drinks. These systems and methods are based on arefrigeration cycle with low startup times and a pod-machine interfacethat is easy to use and provides extremely efficient heat transfer. Someof the pods described can be sterilized (e.g., using retortsterilization or aseptic filling) and used to store ingredientsincluding, for example, dairy products at room temperature for up to 18months. These machines are described in more detail in U.S. patentapplication Ser. No. 16/459,176 (attorney docket number 47354-0009001)filed Jul. 1, 2019 and incorporated herein by reference in its entirety.

A significant challenge in the design of ice cream machines is theability to cool a pod from room temperature to the draw temperature asquickly as possible, preferably within two minutes. Some machines reducethe residence time the ice cream remains in the ice cream machine byreaching the draw temperature as quickly as possible. This can beachieved by mixing and cooling as quickly as possible.

The machines and processes described in this specification create icecream with the majority of the ice crystals below 50 μm and often themajority is below 30 μm in a single serve pod. In order to still be ableto dispense the ice cream out of the pod into a bowl or dish without theice cream contacting the machine, a draw temperature or dispensingtemperature of the ice cream should be between −3° to −8° C. (26.6° F.to 17.6° F.) and preferably between −3° to −6° C. (26.6° F. to 21.2°F.).

The machines and processes described in this specification use a novelfeature of increasing the rotational speed during freezing anddispensing, which is counter-intuitive. The machines described in thisspecification can use a mixing paddle that begins rotating slowly, butas the ice cream starts to freeze from liquid to solid, the rotationalspeed is increased requiring much more power to overcome the increase inmixing paddle torque. Normally as torque increases one would slow downthe rotational speed of the mixing paddle to keep the power requirementconstant. In some machines, the rotational speed of the mixing paddle isincreased during freezing process from 100 RPM to 1200 RPM to reducefreeze times and reduce ice crystal size to be low, around 50 μm.

Furthermore, by increasing the rotational speed of the mixing paddle,ice on the inner diameter of the pod is melted, which is opposite theintended function of the pod wall to freeze the ice cream quickly. Thefreeze time for the ice cream increases by melting the ice crystals atthe pod wall with the extra friction generated by the high rotationalspeed of the mixing paddle. This is opposite the typical goal ofreducing consumer the wait time for the ice cream to freeze anddispense. For at least these reasons, increasing the rotational speed ofthe mixing paddle above a threshold of about 200 RPM iscounter-intuitive.

The rotational speed of the impeller mixing paddle is increased to drawair into the frozen confection to achieve improved overrun (preferablyat least 30% overrun). Rotation of the helical profile of the mixingpaddle (for example, the helical profile of the mixing paddle 950 isshown in FIG. 34A) also generates downward pressure to extrude the icecream out of the exit port of the pod.

Furthermore, as previously described, the combination of spinning themixing paddle quickly and cooling rapidly at the walls of the pod allowsthe cooled ice cream to mix properly within the pod and maintain smallice crystal size which is directly correlated to ice cream smoothness.This is in part because of scraping the chilled ice cream from the wallsof the pod and forcing it to the center of the pod where the temperatureis warmer. Optimal performance of the ice cream machine relies of havingboth efficient cooling at the walls of the pod and rapid scraping/mixingof the contents of the pod. A machine with efficient cooling but withoutrapid scraping/mixing and vice versa would be less optimal.

The ice cream mix described in this specification uses a novel featureof includes minimal or no stabilizers and emulsifiers. The absence ornear absence of stabilizers, emulsifiers, and unnatural products, isconsidered a “clean label”. The ice cream mix described in thisspecification includes milk, cream, sugar and powder milk. By includingthese features in the ice cream mix, the resulting ice cream has amajority of ice crystals under 25 μm in diameter.

For example, a clean label formulation for a 150 g serving of ice creamcan include the following proportions: 48 g of whole milk, 67 g of heavycream (no gums), 24 g of white sugar, and 11 g of non-fat dry milkpowder.

FIG. 3A is a perspective view of a machine 100 for cooling food ordrinks. FIG. 3B shows the machine without its housing. The machine 100reduces the temperature of ingredients in a pod containing theingredients. Most pods include a mixing paddle used to mix theingredients before dispensing the cooled or frozen products. In someinstances, the mixing paddle can be part of the machine and insertedinto the pod. In some instances, the mixing paddle can be used more thanonce. In some instances, the machine will not dispense the frozenconfection and in this case the frozen confection can be scooped out ofthe pod with a spoon.

The machine 100 includes a body 102 that includes a compressor, acondenser, a fan, an evaporator, capillary tubes, a control system, alid system and a dispensing system with a housing 104 and a pod-machineinterface 106. The pod-machine interface 106 includes an evaporator 108of a refrigeration system 109 whose other components are disposed insidethe housing 104. As shown on FIG. 3B, the evaporator 108 defines areceptacle 110 sized to receive a pod.

A lid 112 is attached to the housing 104 via a hinge 114. The lid 112can rotate between a closed position covering the receptacle 110 (FIG.3A) and an open position exposing the receptacle 110 (FIG. 3B). In itsclosed position, the lid 112 covers the receptacle 110 and is locked inplace. In the machine 100, a latch 116 on the lid 112 engages with alatch recess 118 on the pod-machine interface 106. A latch sensor 120 isdisposed in the latch recess 118 to determine if the latch 116 isengaged with the latch recess 118. A processor 122 is electronicallyconnected to the latch sensor 120 and recognizes that the lid 112 isclosed when the latch sensor 120 determines that the latch 116 and thelatch recess 118 are engaged. Not all machines include latch sensors.

An auxiliary cover 115 rotates upward as the lid 112 is moved from itsclosed position to its open position. A slot in the auxiliary cover 115receives a handle of the lid 112 during this movement. Some auxiliarycovers slide into the housing when the lid moves into the open position.

In the machine 100, the evaporator 108 is fixed in position with respectto the body 102 of the machine 100 and access to the receptacle 110 isprovided by movement of the lid 112. In some machines, the evaporator108 is displaceable relative to the body 102 and movement of theevaporator 108 provides access to the receptacle 110.

A motor 124 disposed in the housing 104 is mechanically connected to adriveshaft 126 that extends from the lid 112. When the lid 112 is in itsclosed position, the driveshaft 126 extends into the receptacle 110 and,if a pod is present, engages with the pod to move a paddle or paddleswithin the pod. Sometimes the paddle is referred to as an impeller, ablade, a dasher, or a mixing paddle. The processor 122 is in electroniccommunication with the motor 124 and controls operation of the motor124.

In some machines, the shaft associated with the paddle(s) of the podextends outward from the pod and the lid 112 has a rotating receptacle(instead of the driveshaft 126) mechanically connected to the motor 124.In some machines, the motor provides at least 50 ozf-in (ounce-forceinch) of torque at a rotational velocity of at least 100 RPM (rotationsper minute) at the mixing paddle. For example, a torque of 100 ozf-inand a rotational speed of 750 RPM may be used. In some machines, themotor of the mixing paddle provides a torque of up to 400 ozf-in and arotational speed of up to 1,500 RPM.

FIG. 3C is perspective view of the lid 112 shown separately so the belt125 that extends from motor 124 to the driveshaft 126 is visible.Referring again to FIG. 3B, the motor 124 is mounted on a plate thatruns along rails 127. The plate can move approximately 0.25 inches toadjust the tension on the belt 125. During assembly, the plate slidesalong the rails. Springs disposed between the plate and the lid 112 biasthe lid 112 away from the plate to maintain tension in the belt.

FIG. 4A is a perspective view of the machine 100 with the cover of thepod-machine interface 106 illustrated as being transparent to allow amore detailed view of the evaporator 108 to be seen. FIG. 4B is a topview of a portion of the machine 100 without housing 104 and thepod-machine interface 106 without the lid 112. FIGS. 4C and 4D are,respectively, a perspective view and a side view of the evaporator 108.The evaporator 108 is described in more detail in U.S. patentapplication Ser. No. 16/459,388 (attorney docket number 47354-0006001)filed Jul. 1, 2019 and incorporated herein by reference in its entirety.

The evaporator 108 has a clamshell configuration with a first portion128 attached to a second portion 130 by a living hinge 132 on one sideand separated by a gap 134 on the other side. Refrigerant flows to theevaporator 108 from other components of the refrigeration system throughfluid channels 136 (best seen on FIG. 4B). The refrigerant flows throughthe evaporator 108 in internal channels through the first portion 128,the living hinge 132, and the second portion 130.

The space 137 (best seen on FIG. 4B) between the outer wall of theevaporator 108 and the inner wall of the casing of the pod-machineinterface 106 is filled with an insulating material to reduce heatexchange between the environment and the evaporator 108. In the machine100, the space 137 is filled with an aerogel (not shown). Some machinesuse other insulating material, for example, an annulus (such as anairspace), insulating foams made of various polymers, or fiberglasswool.

The evaporator 108 has an open position and a closed position. In theopen position, the gap 134 opens to provide an air gap between the firstportion 128 and the second portion 130. In the machine 100, the firstportion 128 and the second portion 130 are pressed together in theclosed position.

The inner diameter ID of the evaporator 108 is slightly larger in theopen position than in the closed position. Pods can inserted into andremoved from the evaporator 108 while the evaporator is in its openposition. Transitioning the evaporator 108 from its open position to itsclosed position after a pod is inserted tightens the evaporator 108around the outer diameter of the pod. For example, the machine 100 isconfigured to use pods with 2.085″ outer diameter. The evaporator 108has an inner diameter of 2.115″ in the open position and an innerdiameter inner diameter of 2.085″ in the closed position. The evaporator108 has an inner diameter of 2.115 inches in its open position and aninner diameter inner diameter of 2.085 inches in its closed position.Some machines have evaporators sized and configured to cool other pods.

The evaporator is sized to easily receive a pod in the open position andengage the pod in the closed position. Instead of a clamshellconfiguration, some evaporators can have multiple pieces that have anopened and closed position that do not hinge but can slide into closeproximity with one another. Some evaporators can have a tube connectingthe cooling channels between the various pieces of the evaporator. Someevaporators can be frustoconical. Some evaporators have first and secondportions that are pressed towards each other and a gap between them isreduced, but a space between the first and second portions exists in theclosed position.

Some machines have evaporators sized and configured to cool other pods.The pods can be formed from commercially available can sizes, forexample, “slim” cans with diameters ranging from 2.080 inches-2.090inches and volumes of 180 milliliters (ml)-300 ml, “sleek” cans withdiameters ranging from 2.250 inches-2.400 inches and volumes of 180ml-400 ml and “standard” size cans with diameters ranging from 2.500inches-2.600 inches and volumes of 200 ml-500 ml. The machine 100 isconfigured to use pods with 2.085±0.10 inches outer diameter. Some podshave an inner diameter of 2.065 inches to 2.075 inches to allow themixing paddle with a diameter of 2.045 to 2.055 inches, respectively, torotate at an RPM of 100 to 1,500 RPM, resulting in 6,000 to 93,000square inches scraped per minute.

With an inner diameter of about 2.085 inches, the pod can accommodate amixing paddle with a diameter of about 2.065 inches. The mixing paddlecan revolve in the pod at rotational speeds ranging between 100 RPM and1,500 RPM. During this time a single blade edge of the mixing paddlescrapes the internal walls of the pod at rates ranging from 3,100 to46,500 square inches per minute. The scraped area per minute multiplieswith each scraping edge on the mixing paddle (i.e., a mixing paddle withtwo edges would scrape approximately 6,200 to 93,000 square inches perminute). As previously described, this scraping and mixing process helpsdistribute the ice crystals that formed at the wall of the pod to theinterior of the pod.

Some pods are pressurized to have an internal pressure of around 5-100psi gauge pressure. Some pods have a decorative external coating of nomore than 10-50 microns thickness (e.g., less than 50 microns). Thickerexternal coatings can insulate the pod and interfere with heat transferduring cooling of the pod. Some pods do not have an internal or externalcoating on the ends.

In addition to cylindrical pods, some pods are frustoconical (e.g.,frustoconical with an open end). Some pods do not require a dispensingport because the frozen confection can be spooned out from the open endof the pod.

In addition to single-use pods, some pods are reusable. Some pods areused, washed, and reused. Some pods are be purchased empty and filledbefore use. Some pods are be purchased or acquired full, used, andrefilled by a user or by the machine. Some pods are sterilized after useand sterilized after refill using to enable room temperature storage.Some pods include resealed features that allow the pod to be refilledand resealed. Some pods include a reusable protrusion for dispensing thefrozen confection of the pod from the machine. Some pods can bepurchased empty and used with a home ice cream making kit withclean-label ingredients.

The closed position of evaporator 108 improves heat transfer betweeninserted pod 150 and the evaporator 108 by increasing the contact areabetween the pod 150 and the evaporator 108 and reducing or eliminatingan air gap between the wall of the pod 150 and the evaporator 108. Insome pods, the pressure applied to the pod by the evaporator 108 isopposed by the mixing paddles, pressurized gases within the pod, or bothto maintain the casing shape of the pod. Evaporator 108 can provide aclosure force against the pod 150 of approximately 10-50 lbf(pound-force) and an approximate torque clamping force of 1,000 to 1,500ozf-in.

In the evaporator 108, the relative position of the first portion 128and the second portion 130 and the size of the gap 134 between them iscontrolled by two bars 138 connected by a bolt 140 and two springs 142.Each of the bars 138 has a threaded central hole through which the bolt140 extends and two end holes engaging the pins 144. Each of the twosprings 142 is disposed around a pin 144 that extends between the bars138. Some machines use other systems to control the size of the gap 134,for example, circumferential cable systems with cables that extendaround the outer diameter of the evaporator 108 with the cable beingtightened to close the evaporator 108 and loosened to open theevaporator 108. In other evaporators, there are a plurality of bolts andend holes, one or more than two springs, and one or more than engagingpins.

One bar 138 is mounted on the first portion 128 of the evaporator 108and the other bar 138 is mounted on the second portion 130 of theevaporator 108. In some evaporators, the bars 138 are integral to thebody of the evaporator 108 rather than being mounted on the body of theevaporator. The springs 142 press the bars 138 away from each other. Thespring force biases the first portion 128 and the second portion 130 ofthe evaporator 108 away from each at the gap 134. Rotation of the bolt140 in one direction increases a force pushing the bars 138 towards eachand rotation of the bolt in the opposite direction decreases this force.When the force applied by the bolt 140 is greater than the spring force,the bars 138 bring the first portion 128 and the second portion 130 ofthe evaporator together.

The machine 100 includes an electric motor 146 (shown on FIG. 4B) thatis operable to rotate the bolt 140 to control the size of the gap 134.Some machines use other mechanisms to rotate the bolt 140. For example,some machines use a mechanical linkage, for example, between the lid 112and the bolt 140 to rotate the bolt 140 as the lid 112 is opened andclosed. Some machines include a handle that can be attached to the boltto manually tighten or loosen the bolt. Some machines have a wedgesystem that forces the bars into a closed position when the machine lidis shut. This approach may be used instead of the electric motor 146 orcan be provided as a backup in case the motor fails.

The electric motor 146 is in communication with and controlled by theprocessor 122 of the machine 100. Some electric drives include a torquesensor that sends torque measurements to the processor 122. Theprocessor 122 signals to the motor to rotate the bolt 140 in a firstdirection to press the bars 138 together, for example, when a pod sensorindicates that a pod is disposed in the receptacle 110 or when the latchsensor 120 indicates that the lid 112 and pod-machine interface 106 areengaged. It is desirable that the clamshell evaporator be shut andholding the pod in a tightly fixed position before the lid closes andthe shaft pierces the pod and engages the mixing paddle. Thispositioning can be important for shaft-mixing paddle engagement. Theprocessor 122 signals to the electric drive to rotate the bolt 140 inthe second direction, for example, after the food or drink beingproduced has been cooled/frozen and dispensed from the machine 100,thereby opening the evaporator gap 134 and allowing for easy removal ofpod 150 from evaporator 108.

The base of the evaporator 108 has three bores 148 (see FIG. 4C) whichare used to mount the evaporator 108 to the floor of the pod-machineinterface 106. All three of the bores 148 extend through the base of thesecond portion 130 of the evaporator 108. The first portion 128 of theevaporator 108 is not directly attached to the floor of the pod-machineinterface 106. This configuration enables the opening and closingmovement described above. Other configurations that enable the openingand closing movement of the evaporator 108 can also be used. Somemachines have more or fewer than three bores 148. Some evaporators aremounted to components other than the floor of the pod-machine interface,for example, the dispensing mechanism.

Many factors affect the performance of a refrigeration system. Importantfactors include mass velocity of refrigerant flowing through the system,the refrigerant wetted surface area, the refrigeration process, the areaof the pod/evaporator heat transfer surface, the mass of the evaporator,and the thermal conductivity of the material of the heat transfersurface. Extensive modeling and empirical studies in the development ofthe prototype systems described in this specification have determinedthat appropriate choices for the mass velocity of refrigerant flowingthrough the system and the refrigerant wetted surface area are the mostimportant parameters to balance to provide a system capable of freezingup to 10-12 ounces of confection in less than 2 minutes.

The evaporators described in this specification have the followingcharacteristics:

Mass Velocity 60,000 to 180,000 lb/ (hour feet squared) RefrigerantWetted Surface 35 to 110 square inches Area Pressure drop Through lessthan 2 psi pressure drop Refrigeration Process across the evaporatorPod/Evaporator Heat 15 to 50 square inches Transfer Surface Mass ofEvaporator 0.100 to 1.50 pounds Conductivity of the Material 160 W/mKThe following paragraphs describe the significance of these parametersin more detail.

Mass velocity accounts for the multi-phase nature or refrigerant flowingthrough an evaporator. The two-phase process takes advantage of the highamounts of heat absorbed and expended when a refrigerant fluid (e.g.,R-290 propane) changes state from a liquid to gas and a gas to a liquid,respectively. The rate of heat transfer depends in part on exposing theevaporator inner surfaces with a new liquid refrigerant to vaporize andcool the liquid ice cream mix. To do this the velocity of therefrigerant fluid must be high enough for vapor to channel or flow downthe center of the flow path within the walls of evaporator and forliquid refrigerant to be pushed thru these channel passages within thewalls. One approximate measurement of fluid velocity in a refrigerationsystem is mass velocity—the mass flow of refrigerant in a system perunit cross sectional area of the flow passage in units ofpounds/(hour-square foot) (lb/hr ft²). Velocity as measured infeet/second (ft/s) (a more familiar way to measure “velocity”) isdifficult to apply in a two-phase system since the velocity (ft/s) isconstantly changing as the fluid flow changes state from liquid to gas.If liquid refrigerant is constantly sweeping across the evaporatorwalls, it can be vaporized and new liquid can be pushed against the wallof the cooling channels by the “core” of vapor flowing down the middleof the passage. At low velocities, flow separates based on gravity andliquid remains on the bottom of the cooling passage within theevaporator and vapor rises to the top side of the cooling passagechannels. If the amount of area exposed to liquid is reduced by half,for example, this could cut the amount of heat transfer almost half.

According to the American Society of Heating, Refrigerating andAir-Conditioning Engineers (ASHRAE), a mass velocity of 150,000 lb/hrft{circumflex over ( )}2 maximizes performance for the majority of theevaporator flow path. Mass velocity is one of the parameters that mustbe balanced to optimize a refrigerant system. The parameters that affectthe performance of the evaporator are mass flow rate, convective heattransfer coefficient, and pressure drop. The nominal operating pressureof the evaporator is determined by the required temperature of theevaporator and the properties of the refrigerant used in the system. Themass flow rate of refrigerant through the evaporator must be high enoughfor it to absorb the amount of thermal energy from the confection tofreeze it, in a given amount of time. Mass flow rate is primarilydetermined by the size of the compressor. It is desirable to use thesmallest possible compressor to reduce, cost, weight and size. Theconvective heat transfer coefficient is influenced by the mass velocityand wetted surface area of the evaporator. The convective heat transfercoefficient will increase with increased mass velocity. However,pressure drop will also increase with mass velocity. This in turnincreases the power required to operate the compressor and reduces themass flow rate the compressor can deliver. It is desirable to design theevaporator to meet performance objectives while using the smallest leastexpensive compressor possible. We have determined that evaporators witha mass velocity of 75,000-125,000 lb/hr ft{circumflex over ( )}2 areeffective in helping provide a system capable of freezing up to 12ounces of confection in less than 2 minutes. The latest prototype has amass velocity of approximately 100,000 lb/hr ft{circumflex over ( )}2and provides a good balance of high mass velocity, manageable pressuredrop in the system (under 2 psi), and a reasonable sized compressorbelow 12 cc displacement

In some systems, the refrigeration system cools the pod with acompressor using a two-phase refrigerant fluid, such as R134A, R22,R600a, or R290. In some systems the compressor is a reciprocatingcompressor or a rotary compressor. Direct Current (DC) compressors witha variable motor speed allow for increased displacement towards thebeginning of the refrigeration cooling cycle of the pod (e.g., first 45seconds of cooling the pod) and slow down the motor speed towards theend of the cooling cycle of the pod in order to increase the efficiencyof the freezing process while maintaining the pressure drop. In somesystems, the DC compressor can have a variable motor speed that isadjusted depending on the load on the machine's refrigeration cycle.

In some systems, the use of a natural refrigerant, such as R290, canmeet objectives of international protocols, such as Montreal and Kyoto,as well as help reduce environmental issues, such as ozone depletion andglobal warming. These protocols and environmental issues typicallysuggest that R22 and R134A refrigerants be phased out.

Thermo-physical properties of refrigerants determine an energyperformance of the refrigeration system. The following table showsthermo-physical properties for refrigerants R22 and R290, at anevaporating temperature of 10° C. and condensing temperature of 45° C.

Temp Refrigerant Refrigerant Property (Degrees C.) State R22 R290Saturation Pressure 10 Liquid 0.640 0.601 (MPa) 45 Vapor 1.729 1.534Density (kg/m{circumflex over ( )}3) 10 Liquid 1253.8 517.56 45 Vapor75.45 34.14 Viscosity (microPa-s) 10 Liquid 197.97 115.69 45 Vapor 13.699.13 Thermal conductivity 10 Liquid 0.0911 0.101 (W/m deg. C.) 45 Vapor0.0135 0.0224 Specific heat 10 Liquid 1.1836 2.5318 (kj/kg deg C.) 45Vapor 1.0487 2.3714

The lower liquid density of R290 refrigerant denotes the lowerrequirement of refrigerant mass resulting in lower friction and betterheat transfer coefficients in the evaporator and condenser. Refrigerantviscosity is the major source of irreversibility and influencescondensation and boiling heat transfer coefficients. R290 refrigeranthas lower viscosity and higher thermal conductivity which improves theperformance of condenser and evaporator. The higher specific heat ofR290 gives lower discharge temperatures.

Another important factor that affects performance in an evaporator isthe surface area wetted by refrigerant which is the area of all thecooling channels within the evaporator as long as at least some liquidrefrigerant is present throughout these channels. Increasing the wettedsurface area can improve heat transfer characteristics of an evaporator.However, increasing the wetted surface area can increase the mass of theevaporator which would increase thermal inertia and degrade heattransfer characteristics of the evaporator.

The amount of heat that can be transferred out of the liquid in a pod isproportional ice cream mix to the surface area of the pod/evaporatorheat transfer surface. A larger surface area is desirable but increasesin surface area can require increasing the mass of the evaporator whichwould degrade heat transfer characteristics of the evaporator. We havedetermined that evaporators in which the area of the pod/evaporator heattransfer surface is between 20 and 40 square inches are effectivelycombined with the other characteristics to help provide a system capableof freezing up to 12 ounces of confection in less than 2 minutes.

Thermal conductivity is the intrinsic property of a material whichrelates its ability to conduct heat. Heat transfer by conductioninvolves transfer of energy within a material without any motion of thematerial as a whole. An evaporator with walls made of a highconductivity material (e.g., aluminum) reduces the temperaturedifference across the evaporator walls. Reducing this temperaturedifference reduces the work required for the refrigeration system tocool the evaporator to the right temperature.

The temperature of the pod can be measured using a temperature sensor,such as a thermocouple. In some machines, a thermocouple physicallytouching the exterior surface of the pod can be used to measure thetemperature of the pod, or the thermocouple can be provided directly onthe exterior of the pod. In some machines, the sensor(s) penetrateradially through the evaporator and, in some cases, are spring loaded toensure consistent force at the sensor tip. The sensor can be insulatedthermally from the evaporator so it only senses the temperature of theoutside of the pod. Pods can be made of approximately 0.004 to 0.008inch thick aluminum such that the pod temperature is effectively thesame as the temperature of the contents. Using these temperatures theprocess would be controllable in several ways: (i) by varying the mixerspeed depending on how quickly the product freezes, (ii) by stopping thefreezing process when the target temperature is achieved, and (iii)during the dispensing process, by sensing when the pod is empty andending the dispensing process at that time, instead of spinning themixing paddle in an empty pod, which can be noisy.

For the desired heat transfer to occur, the evaporator must be cooled.The greater the mass of the evaporator, the longer this cooling willtake. Reducing evaporator mass reduces the amount of material that mustbe cooled during a freezing cycle. An evaporator with a large mass willincrease the time require to freeze up to 12 ounces of confection.

The effects of thermal conductivity and mass can be balanced by anappropriate choice of materials. There are materials with higher thermalconductivity than aluminum such as copper. However, the density ofcopper is greater that the density of aluminum. For this reason, someevaporators have been constructed that use high thermal conductivecopper only on the heat exchange surfaces of the evaporator and usealuminum everywhere else.

FIGS. 5A-5F show components of the pod-machine interface 106 that areoperable to open pods in the evaporator 108 to dispense the food ordrink being produced by the machine 100. This is an example of oneapproach to opening pods but some machines and the associated pods useother approaches.

FIG. 5A is a partially cutaway schematic view of the pod-machineinterface 106 with a pod 150 placed in the evaporator 108. FIG. 5B is aschematic plan view looking upwards that shows the relationship betweenthe end of the pod 150 and the floor 152 of the pod-machine interface106. The floor 152 of the pod-machine interface 106 is formed by adispenser 153. FIGS. 5C and 5D are perspective views of a dispenser 153.FIGS. 5E and 5F are perspective views of an insert 154 that is disposedin the dispenser 153. The insert 154 includes an electric motor 146operable to drive a worm gear 157 floor 152 of the pod-machine interface106. The worm gear 157 is engaged with a gear 159 with an annularconfiguration. An annular member 161 mounted on the gear 159 extendsfrom the gear 159 into an interior region of the pod-machine interface106. The annular member 161 has protrusions 163 that are configured toengage with a pod inserted into the pod-machine interface 106 to openthe pod. The protrusions 163 of the annular member 161 are fourdowel-shaped protrusions. Some annular gears have more protrusions orfewer protrusions and the protrusions can have other shapes, forexample, “teeth”.

The pod 150 includes a body 158 containing a mixing paddle 160 (see FIG.5A). The pod 150 also has a base 162 defining an aperture 164 and a cap166 extending across the base 162 (see FIG. 5B). The base 162 isseamed/fixed onto the body 158 of the pod 150. The base 162 includes aprotrusion 165. The cap 166 mounted over base 162 is rotatable aroundthe circumference/axis of the pod 150. In use, when the product is readyto be dispensed from the pod 150, the dispenser 153 of the machineengages and rotates the cap 166 around the first end of the pod 150. Cap166 is rotated to a position to engage and then separate the protrusion165 from the rest of the base 162. The pod 150 and its components aredescribed in more detail with respect to FIGS. 8A-8B.

The aperture 164 in the base 162 is opened by rotation of the cap 166.The pod-machine interface 106 includes an electric motor 146 withthreading that engages the outer circumference of a gear 168. Operationof the electric motor 146 causes the gear 168 to rotate. The gear 168 isattached to an annular member 161 and rotation of the gear 168 rotatesthe annular member 161. The gear 168 and the annular member 161 are bothannular and together define a central bore through which food or drinkcan be dispensed from the pod 150 through the aperture 164 withoutcontacting the gear 168 or the annular member 161. When the pod 150 isplaced in the evaporator 108, the annular member 161 engages the cap 166and rotation of the annular member 161 rotates the cap 166.

FIG. 6 is a schematic of the refrigeration system 109 that includes theevaporator 108. The refrigeration system also includes a condenser 180,a suction line heat exchanger 182, an expansion device 184, and acompressor 186. The expansion device 184 can include a valve or acapillary tube both of which could be used in the refrigeration system109. High-pressure, liquid refrigerant flows from the condenser 180through the suction line heat exchanger 182 and the expansion device 184to the evaporator 108. The expansion device 184 restricts the flow ofthe liquid refrigerant fluid and lowers the pressure of the liquidrefrigerant as it leaves the expansion device 184. The low-pressureliquid then moves to the evaporator 108 where heat is absorbed from apod 150 and its contents in the evaporator 108 changes the refrigerantfrom a liquid to a gas. The gas-phase refrigerant flows from theevaporator 108 to the compressor 186 through the suction line heatexchanger 182. In the suction line heat exchanger 182, the cold vaporleaving the evaporator 108 pre-cools the liquid leaving the condenser180. The refrigerant enters the compressor 186 as a low-pressure gas andleaves the compressor 186 as a high-pressure gas. The gas then flows tothe condenser 180 where heat exchange cools and condenses therefrigerant to a liquid.

The refrigeration system 109 includes a first bypass line 188 or valveand second bypass line 190 or valve. The first bypass line 188 directlyconnects the discharge of the compressor 186 to the inlet of thecompressor 186. Disposed on the both the first bypass line and secondbypass line are bypass valves that open and close the passage to allowrefrigerant bypass flow. Diverting the refrigerant directly from thecompressor discharge to the inlet can provide evaporator defrosting andtemperature control without injecting hot gas to the evaporator. Thefirst bypass line 188 also provides a means for rapid pressureequalization across the compressor 186, which allows for rapidrestarting (i.e., freezing one pod after another quickly). The secondbypass line 190 enables the application of warm gas to the evaporator108 to defrost the evaporator 108. The bypass valves may be, forexample, solenoid valves or throttle valves. An additional bypass valvecan be used (not shown) to direct warm air along the length of themixing paddle 160 to help remove product sticking to the mixing paddle160.

FIGS. 7A and 7B are views of a prototype of the condenser 180. Thecondenser has internal channels 192. The internal channels 192 increasethe surface area that interacts with the refrigerant cooling therefrigerant quickly. These images show micro-channel tubing which areused because they have small channels which keeps the coolant velocityup and are thin wall for good heat transfer and have little mass toprevent the condenser for being a heat sink.

FIGS. 10A and 10B show an example of a pod 150 for use with the machine100 described with respect to FIGS. 3A-5F. FIG. 8A is a side view of thepod 150. FIG. 8B is a schematic side view of the pod 150 and the mixingpaddle 160 disposed in the body 158 of the pod 150.

The pod 150 is sized to fit in the receptacle 110 of the machine 100.The pods can be sized to provide a single serving of the food or drinkbeing produced. Typically, pods have a volume between 6 and 18 fluidounces. The pod 150 has a volume of approximately 8.5 fluid ounces.

The body 158 of the pod 150 is an aluminum beverage can that containsthe mixing paddle 160. The body 158 extends from a first end 210 at thebase to a second end 212 and has a circular cross-section. The first end210 has a diameter DUE that is slightly larger than the diameter DLE ofthe second end 212. This configuration facilitates stacking multiplepods 150 on top of one another with the first end 210 of one podreceiving the second end 212 of another pod.

A sidewall 214 connects the first end 210 to the second end 212. Thewall 214 has a first neck 216, second neck 218, and a barrel 220 betweenthe first neck 216 and the second neck 218. The barrel 220 has acircular cross-section with a diameter DB. The diameter DB is largerthan both the diameter DUE of the first end 210 and the diameter DLE ofthe second end 212. The first neck 216 connects the barrel 220 to thefirst end 210 and slopes as the first neck 216 extends from the smallerdiameter DUE to the larger diameter DB the barrel 220. The second neck218 connects the barrel 220 to the second end 212 and slopes as thesecond neck 218 extends from the larger diameter DB of the barrel 220 tothe smaller diameter DLE of the second end 212. The second neck 218 issloped more steeply than the first neck 216 as the second end 212 has asmaller diameter than the first end 210.

This configuration of the pod 150 provides increased material usage;i.e., the ability to use more base material (e.g., aluminum) per pod.This configuration further assists with the columnar strength of thepod.

The pod 150 is designed for good heat transfer from the evaporator tothe contents of the pod. The body 158 of the pod 150 is made of aluminumand is between 5 and 50 microns thick. The bodies of some pods are madeof other materials, for example, tin, stainless steel, and variouspolymers such as polyethylene terephthalate (PTE).

Pod 150 may be made from a combination of different materials to assistwith the manufacturability and performance of the pod. In oneembodiment, the pod walls and the second end 212 may be made of Aluminum3104 while the base may be made of Aluminum 5182.

In some pods, the internal components of the pod are coated with alacquer to prevent corrosion of the pod as it comes into contact withthe ingredients contained within pod. This lacquer also reduces thelikelihood of “off notes” of the metal in the food and beverageingredients contained within pod. For example, a pod made of aluminummay be internally coated with one or a combination of the followingcoatings: Sherwin Williams/Valspar V70Q11, V70Q05, 32SO2AD, 40Q60AJ; PPGInnovel 2012-823, 2012-820C; and/or Akzo Nobel Aqualure G1 50. Othercoatings made by the same or other coating manufacturers may also beused.

Some mixing paddles are made of similar aluminum alloys and coated withsimilar lacquers/coatings. For example, Whitford/PPG coating 8870 may beused as a coating for mixing paddles. The mixing paddle lacquer may haveadditional non-stick and hardening benefits for mixing paddle. Somemixing paddles are made of AL 5182-H48 or other aluminum alloys. Somemixing paddles exhibit a tensile strength of 250-310 MPa minimum, ayield strength of 180-260 MPa minimum, and an elongation at break of4%-12%.

In some machines, the mixing paddles can be reusable by removing fromthe pod, washing them, and reusing them in the same or another pod.

In addition to the functionally of the mixing paddles previouslydiscussed, some machines oscillate and/or vibrate the mixing paddles tohelp remove product sticking to the mixing paddle. This approach can beenabled by a machine (such as machine 100) which includes a solenoidthat oscillates and/or vibrates the mixing paddle.

Other pod-machine interfaces that can be used with this and similarmachines are described in more detail in U.S. patent application Ser.No. 16/459,322 (attorney docket number 47354-0010001) filed Jul. 1, 2019and incorporated herein by reference in its entirety.

Some pods include a seal configured to be broken upon an applied torqueby the mixing motor. Such a pod design can be easier and cheaper tomanufacture for compatibility with machines.

FIGS. 9A-9C illustrate the engagement between the driveshaft 126 of themachine 100 and the mixing paddle 160 of a pod 150 inserted in themachine 100. FIGS. 9A and 9B are perspective views of the pod 150 andthe driveshaft 126. In use, the pod 150 is inserted into the receptacle110 of the evaporator 108 with the first end 210 of the pod 150downward. This orientation exposes the second end 212 of the pod 150 tothe driveshaft 126 as shown in FIG. 9A. Closing the lid 112 (see FIG.3A) presses the driveshaft 126 against the second end 212 of the pod 150with sufficient force that the driveshaft 126 pierces the second end 212of the pod 150. In some machines, the downward force of the piercingaction of the driveshaft 126 into the second end 212 of the pod 150 isapproximately 50 lbf. Downward forces of between 15-65 lbf are effectivein piercing the second end of the pod without damaging other portions ofthe pod.

FIG. 9B shows the resulting hole and the mixing paddle 160 visiblethrough the hole. The driveshaft 126 is shown offset for ease ofviewing. FIG. 9C is a cross-section of a portion of the pod 150 with thedriveshaft 126 engaged with the mixing paddle 160 after the lid isclosed. Typically, there is not a tight seal between the driveshaft 126and the pod 150 so that air can flow in as the frozen confection isevacuating/dispensing out the other end of the pod 150. In analternative embodiment, there is a tight seal such that the pod 150retains pressure in order to enhance contact between the pod 150 andevaporator 108.

Some mixing paddles contain a funnel or receptacle configuration thatreceives the punctured end of the second end of the pod when the secondend is punctured by driveshaft.

FIG. 10A shows the first end 210 of the pod 150 with the cap 166 spacedapart from the base 162 for ease of viewing. FIGS. 11A-11G illustraterotation of the cap 166 around the first end 210 of the pod 150 to cutand carry away protrusion 165 of base 162 and expose aperture 164extending through the base 162.

The base 162 is manufactured separately from the body 158 of the pod 150and then attached (for example, by crimping or seaming) to the body 158of the pod 150 covering an open end of the body 158. The protrusion 165of the base 162 can be formed, for example, by stamping, deep drawing,or heading a sheet of aluminum being used to form the base. Theprotrusion 165 is attached to the remainder of the base 162, forexample, by a weakened score line 173. The scoring can be a verticalscore into the base of the aluminum sheet or a horizontal score into thewall of the protrusion 165. For example, the material can be scored froman initial thickness of 0.008 inches to 0.010 inches (e.g., the initialthickness can be 0.008 inches) to a post-scoring thickness of 0.001inches-0.008 inches (e.g, the score thickness can be 0.002 inches).

FIG. 10B shows a cross section of the first end 210 of the pod 150illustrating the base 162, the protrusion 165, and the weakened scoreline 173. The weakened score line 173 is 0.006 inches deep into 0.008inches thick aluminum base lid material.

In some embodiments, there is no post-stamping scoring but rather thewalls are intentionally thinned for ease of rupture. In another version,there is not variable wall thickness but rather the cap 166 combinedwith force of the machine dispensing mechanism engagement are enough tocut the 0.008 inches to 0.010 inches wall thickness on the protrusion165. With the scoring, the protrusion 165 can be lifted and sheared offthe base 162 with 5-75 pounds of force, for example between 15-40 poundsof force. In some cases, the diameter of a circular protrusion is0.375-0.850 inches (e.g., 0.575 inches in diameter as seen in FIG. 10B).In some cases, an area of the protrusion 165 is 0.1-0.5 in² (e.g., 0.26in² as seen in FIGS. 10B-10D). In some cases, the area of the base 162is 2.0-5.0 in² (e.g. 3.95 in² as seen in FIGS. 10B-10D). The area of thecircular protrusion is a fraction of the total surface area of the base162. In some cases, a diameter of the base 162 is 1.5-3.0 inches (e.g.,2.244 inches as seen in FIGS. 10B-10D). In some cases, an area ratio ofthe circular protrusion 165 to the base 162 is 0.01-0.50 (e.g., 0.065 asseen in FIGS. 10B-10D).

In some cases, the protrusion and corresponding opening when protrusionis sheared and carried away has a surface area between 5% to 30% of theoverall pod end surface area. In some cases, the protrusion may becircular in shape, have a tear-drop, have a kidney shape, or be of anyarbitrary shape. In some cases the protrusion may be round but thescored shape can be either circular in shape, have a tear-drop, have akidney shape, or be of any arbitrary shape.

FIG. 10A shows the cap 166 having a first aperture 222 and a secondaperture 224. The first aperture approximately matches the shape of theaperture 164. The aperture 164 is exposed and extends through the base162 when the protrusion 165 is removed. The second aperture 224 has ashape corresponding to two overlapping circles. One of the overlappingcircles has a shape that corresponds to the shape of the protrusion 165and the other of the overlapping circles is slightly smaller. A ramp 226extends between the outer edges of the two overlapping circles. There isan additional 0.010 to 0.100 inches of material thickness at the top ofthe ramp transition (e.g., 0.070 inches). This extra height helps tolift and rupture the protrusion's head and open the aperture during therotation of the cap as described in more detail with reference to FIGS.11A-11G.

FIGS. 11A and 11B show the cap 166 being initially attached to the base162 with the protrusion 165 aligned with and extending through thelarger of the overlapping circles of the second aperture 224. When theprocessor 122 of the machine activates the electric motor 146 to rotatethe gear 168 and the annular member 161, rotation of the cap 166 slidesthe ramp 226 under a lip of the protrusion 165 as shown in FIGS. 11C and11D. Continued rotation of the cap 166 applies a lifting force thatseparates the protrusion 165 from the remainder of the base 162 (seeFIGS. 11E-11G) and then aligns the first aperture 222 of the cap 166with the aperture 164 in the base 162 resulting from removal of theprotrusion 165. The electric motor 146 can apply up to 1,000 ozf-inchesof torque to lift and shear off the protrusion 165. In some machines,the process of removing the protrusion also removes product (frozen ornot) that may accumulate within a recess of the end of the protrusion.

In some machines, the motor 124 slows down during the protrusionshearing process, and then speeds up during the dispensing process. Inthis case, it is advantageous for the driveshaft to rotate withoutstopping or reversing through the mixing, shearing, and dispensing cyclein order to reduce the likelihood of the motor 124 stalling.

Some pods include a structure for retaining the protrusion 165 after theprotrusion 165 is separated from the base 162. In the pod 150, theprotrusion 165 has a head 167, a stem 169, and a foot 171 (best seen inFIG. 11G). The stem 169 extends between the head 167 and the foot 171and has a smaller cross-section that the head 167 and the foot 171. Asrotation of the cap 166 separates the protrusion 165 from the remainderof the base 162, the cap 166 presses laterally against the stem 169 withthe head 167 and the foot 171 bracketing the cap 166 along the edges ofone of the overlapping circles of the second aperture 224. Thisconfiguration retains the protrusion 165 when the protrusion 165 isseparated from the base 162. Such a configuration reduces the likelihoodthat the protrusion falls into the waiting receptacle that when theprotrusion 165 is removed from the base. After the mixing paddle 160 ofthe machine spins and dispenses the frozen confection through theaperture 224, the motor 124 rotates the cap 166 and closes the aperture224 so that any residual product (e.g., ice cream) when melted does notleak out of the pod.

Some pods include other approaches to separating the protrusion 165 fromthe remainder of the base 162. For example, in some pods, the base has arotatable cutting mechanism that is riveted to the base. The rotatablecutting mechanism has a shape similar to that described relative to cap166 but this secondary piece is riveted to and located within theperimeter of base 162 rather than being mounted over and around base162. When the refrigeration cycle is complete, the processor 122 of themachine activates an arm of the machine to rotate the riveted cuttingmechanism around a rivet. During rotation, the cutting mechanismengages, cuts, and carries away the protrusion 165, leaving the aperture164 of base 162 in its place.

In another example, some pods have caps with a sliding knife that movesacross the base to remove the protrusion. The sliding knife is activatedby the machine and, when triggered by the controller, slides across thebase to separate, remove, and collect the protrusion 165. The cap 166has a guillotine feature that, when activated by the machine, may slidestraight across and over the base 162. The cap 166 engages, cuts, andcarries away the protrusion 165. In another embodiment, this guillotinefeature may be central to the machine and not the cap 166 of pod 150. Inanother embodiment, this guillotine feature may be mounted as asecondary piece within base 162 and not a secondary mounted piece as isthe case with cap 166.

Some pods have a dispensing mechanism that includes a pop top that canbe engaged and released by the machine. When the refrigeration cycle iscomplete, an arm of the machine engages and lifts a tab of the pod,thereby pressing the puncturing the base and creating an aperture in thebase. Chilled or frozen product is dispensed through the aperture. Thepunctured surface of the base remains hinged to base and is retainedinside the pod during dispensing. The mixing avoids or rotates over thepunctured surface or, in another embodiment, so that the mixing paddlecontinues to rotate without obstruction. In some pop tops, the arm ofthe machine separates the punctured surface from the base.

FIG. 12 is an enlarged schematic side view of the pod 150. The mixingpaddle 160 includes a central stem 228 and two blades 230 extending fromthe central stem 228. The blades 230 are helical blades shaped to churnthe contents of the pod 150 and to remove ingredients that adhere toinner surface of the body 158 of the pod 150. Some mixing paddles have asingle blade and some mixing paddles have more than two mixing paddles.

Fluids (e.g., liquid ingredients, air, or frozen confection) flowthrough openings 232 in the blades 230 when the mixing paddle 160rotates. These openings reduce the force required to rotate the mixingpaddle 160. This reduction can be significant as the viscosity of theingredients increases (e.g., as ice cream forms). The openings 232 alsoassist in mixing and aerating the ingredients within the pod. In somemachines, the openings 232 represent about 36.5% of the total surfacearea of the mixing paddle 160.

The lateral edges of the blades 230 define slots 234. The slots 234 areoffset so that most of the inner surface of the body 158 is cleared ofingredients that adhere to inner surface of the body by one of theblades 230 as the mixing paddle 160 rotates. Although the mixing paddleis 160 wider than the first end 210 of the body 158 of the pod 150, theslots 234 are alternating slots that facilitate insertion of the mixingpaddle 160 into the body 158 of the pod 150 by rotating the mixingpaddle 160 during insertion so that the slots 234 are aligned with thefirst end 210. In another embodiment, the outer diameter of the mixingpaddle are less than the diameter of the pod 150 opening, allowing for astraight insertion (without rotation) into the pod 150. In anotherembodiment, one blade on the mixing paddle has an outer-diameter that iswider than the second blade diameter, thus allowing for straightinsertion (without rotation) into the pod 150. In this mixing paddleconfiguration, one blade is intended to remove (e.g., scrape)ingredients from the sidewall while the second, shorter diameter blade,is intended to perform more of a churning operation.

Some mixing paddles have one or more blades that are hinged to thecentral stem. During insertion, the blades can be hinged into acondensed formation and released into an expanded formation onceinserted. Some hinged blades are fixed open while rotating in a firstdirection and collapsible when rotating in a second direction, oppositethe first direction. Some hinged blades lock into a fixed, outward,position once inside the pod regardless of rotational directions. Somehinged blades are manually condensed, expanded, and locked.

The mixing paddle 160 rotates clockwise (as observed from above themachine) and removes frozen confection build up from the pod 214 wall.Gravity forces the confection removed from the pod wall to fall towardsfirst end 210. In the counterclockwise direction, the mixing paddle 160rotate, lift and churn the ingredients towards the second end 212. Whenthe paddle changes direction and rotates clockwise the ingredients arepushed towards the first end 210. When the protrusion 165 of the base162 is removed as shown and described with respect to FIG. 11D,clockwise rotation of the mixing paddle dispenses produced food or drinkfrom the pod 150 through the aperture 164. Some paddles mix and dispensethe contents of the pod by rotating a first direction. Some paddles mixby moving in a first direction and dispense by moving in the seconddirection when the pod is opened. Some mixing paddles do not reversedirection.

The central stem 228 defines a recess 236 that is sized to receive thedriveshaft 126 of the machine 100. The recess and driveshaft 126 have asquare or faceted cross section so that the driveshaft 126 and themixing paddle 160 are rotatably constrained. When the motor rotates thedriveshaft 126, the driveshaft rotates the mixing paddle 160. In someembodiments, the cross section of the driveshaft is a different shapeand the cross section of the recess is compatibly shaped. In some casesthe driveshaft and recess are threadedly connected. In some pods, therecess contains a mating structure that grips the driveshaft torotationally couple the driveshaft to the paddle.

FIGS. 13A-13D show a body 1300 that is substantially similar to the bodyor can 158 of the pod 150. However, the body 1300 has two seamed ends1302, 1304 instead of a domed end of the body 158 of the pod 150. Byeliminating the domed end, body 1300 is easier to manufacture usingmethods such as stamping, extruding, or rolling. As shown in theisometric view of FIG. 13D, the body 1300 resembles a hollow tube andincludes a thin walled extrusion 1306. A malleable material such asaluminum can be used to form the body 1300. Each seamed end 1302, 1304features a lip that is configured to be engaged with a corresponding lipof the lid 1308 and seamed together using a seaming machine. FIG. 13Bshows a cross section of the second seamed end 1304. FIG. 13Cillustrates the seaming process between the body 1300 and the lid 1308.In some cases, the body 1300 to lid 1308 seamed connection is similar tothe seam seen in FIG. 35C. In this way, a lid 1308 is attached to eachend of the aluminum pod 1300.

One of the lids 1308 includes a grommet in the center (not shown) torotationally couple the mixing motor to the mixing paddle within thebody 1300 (not shown) and to seal the pod in an initial configuration.The grommet is overmolded, adhered, or fastened to the lid 1308. Thebody 1300, together with two lids 1308, defines a pod.

In these systems and methods, sterilization is typically done before thefreezing of the liquid ice cream mix.

FIG. 14A is a photo of a retort machine and FIG. 14B is a photo ofretort sterilization chambers inside a retort machine. As previouslydescribed, a retort machine is used to sterilize and make a podshelf-stable. To help reduce operations in the factory with theprocesses described in this specification, it is possible to fill thesingle serve pods (cans) with liquid ice cream mix that has not beenpasteurized nor homogenized. Then during the retort sterilizationprocess, for example using the retort machine shown in the images ofFIGS. 14A and 14B, the pods can be shaken back and forth at variousrates, for example 180 cycles per minute at 3 Hz. During the retortprocess, the liquid ice cream sloshes inside the pod (i.e.,homogenizing) while simultaneously being exposed to high temperaturesand high pressures for sterilization.

By using unpasteurized dairy in our pods and performing a retort processon the pod before use, the dairy inside the pod is only pasteurizedonce. This is in contrast to the typical pasteurization processillustrated in FIG. 1 where the dairy is usually pasteurized beforeleaving the dairy factory which means it is pasteurized twice, e.g.,once at the dairy factory and once in our retort process.

The sloshing of the liquid ice cream in the pod can significantlyincrease the heat transfer of 250° F. for 2-15 minutes because theliquid is sloshing around in the can inside the retort vessel. Both thecan and the retort vessels are under pressure. For example, thispressure can be 100 psi. By pasteurizing through retort whilehomogenizing, this approach eliminates steps in the traditionaloperation of making ice cream (e.g., the process of FIG. 1), whichimproves efficiency and reduces cost. This process can give moreauthentic, fresher tasting, and better looking foods, with better color,texture and mouth feel. Recent growth in premium categories indicatesstrong consumer demand for enhanced food quality.

The retort shaking of these pods in and during the retort sterilizationprocess produces much better-quality low acid foods preserved forambient storage. It can also reduce cycle times by some 90% and energyconsumption by up to 50%, compared to conventional batch, static retortprocesses. This quicker retort process is able to reach F₀ lethalityvalue faster providing a reduction in the over-cooked notes and flavorloss of the ice cream and reduction of discoloration often associatedwith the retort process in static or slow agitating retorts. The processis also capable of homogenizing the liquid mix. Homogenizing the liquidmix by shaking quickly is advantageous because two operations areachieved at once, sterilization and homogenization of the liquid icecream mix. FIGS. 14A-14B are photos of retort sterilization chambersthat can include dozens or hundreds of pods and move them back and forthat 3 Hz or up to 180 cycles per minute in order to quicken the heattransfer to minimize the caramelization from cooking the dairy in retortwhile simultaneously homogenizing the liquid ice cream mix.

During this pasteurization process, which can be done using a retortprocess, pasteurized dairy can caramelize and become brown, which can beundesirable. The highest rate of browning, or more generally referred toas color development, can be caused by the presence of fructose whichbegins to caramelize at temperatures of 230° F.

Some of these systems and processes use a retort process that retorts at250° F. even though retorting at higher temperatures is generallypreferred because it would allow the pasteurization process to completein less time. Completing a retort at 250° F. can limit the effect ofbrowning when fructose is removed from the ice cream mix formulation.

The highest rate of the color development can be caused by fructose asthe caramelization process of fructose starts at 230° F. Caramelizationshould not be confused with the Maillard reaction, in which reducingsugar reacts with amino acids. Browning, or the Maillard reaction,creates flavor and changes the color of food. Maillard reactionsgenerally only begin to occur above 285° F. For at least these reasons,our retort temperatures do not exceed 250° F., which would otherwise bepreferred since it would be faster at the sterilization process.

For example, caramelization temperatures of fructose can be 230° F.,galactose can be 320° F., glucose can be 320° F., lactose can be 397°F., and sucrose can be 320° F. In some examples, corn syrup, orhigh-fructose corn syrup (HFCS), when heated to about 113° F., formshydroxymethylfurfural from the breakdown of fructose.

Some of these systems use a pod with a clean label, milk, or sugarcream. Sometimes a gum stabilizer is be used and preferably Gum acacia,gellan gum, pectin and cellulose gum stabilizers can be used which areretort stable. Lactose can be not preferable in retort since it is adisaccharide. Lactose is a sugar composed of galactose and glucosesubunits and can make up about 2 to 8% of milk.

FIG. 15 is a flow chart of a method 250 implemented on the processor 122for operating the machine 100. The method 250 is described withreferences to refrigeration system 109 and machine 100. The method 250may also be used with other refrigeration systems and machines. Themethod 250 is described as producing soft serve ice cream but can alsobe used to produce other cooled or frozen drinks and foods.

The first step of the method 250 is to turn the machine 100 on (step260) and turn on the compressor 186 and the fans associated with thecondenser 180 (step 262). The refrigeration system 109 then idles atregulated temperature (step 264). In the method 250, the evaporator 108temperature is controlled to remain around 0.75° C. but may fluctuate by±0.25° C. Some machines are operated at other idle temperatures, forexample, from 0.75° C. to room temperature (22.0° C.). If the evaporatortemperature is below 0.5° C., the processor 122 opens the bypass valve190 to increase the heat of the system (step 266). When the evaporatortemperature goes over 1° C., the bypass valve 190 is closed to cool theevaporator (step 268). From the idle state, the machine 100 can beoperated to produce ice cream (step 270) or can shut down (step 272).

After inserting a pod, the user presses the start button. When the userpresses the start button, the bypass valve 190 closes, the evaporator108 moves to its closed position, and the motor 124 is turned on (step274). In some machines, the evaporator is closed electronically using amotor. In some machines, the evaporator is closed mechanically, forexample by the lid moving from the open position to the closed position.In some systems, a sensor confirms that a pod 150 is present in theevaporator 108 before these actions are taken.

Some systems include radio frequency identification (RFID) tags or otherintelligent bar codes such as UPC bar or QR codes. Identificationinformation on pods can be used to trigger specific cooling and mixingalgorithms for specific pods. These systems can optionally read theRFID, QR code, or barcode and identify the mixing motor speed profileand the mixing motor torque threshold (step 273).

The identification information can also be used to facilitate direct toconsumer marketing (e.g., over the internet or using a subscriptionmodel). This approach and the systems described in this specificationenable selling ice cream thru e-commerce because the pods are shelfstable. In the subscription mode, customers pay a monthly fee for apredetermined number of pods shipped to them each month. They can selecttheir personalized pods from various categories (e.g., ice cream,healthy smoothies, frozen coffees or frozen cocktails) as well as theirpersonalized flavors (e.g., chocolate or vanilla). In some cases, themachine itself can be rented using a subscription model. In some cases,reusable pods and mixing paddles can be rented as well.

The identification can also be used to track each pod used. In somesystems, the machine is linked with a network and can be configured toinform a vendor as to which pods are being used and need to be replaced(e.g., through a weekly shipment). This method is more efficient thanhaving the consumers go to the grocery store and purchase pods.

These actions cool the pod 150 in the evaporator 108 while rotating themixing paddle 160. As the ice cream forms, the viscosity of the contentsof the pod 150 increases. A torque sensor of the machine 100 measuresthe torque of the motor 124 required to rotate the mixing paddle 160within the pod 150. Once the torque of the motor 124 measured by atorque sensor satisfies a predetermined threshold, the machine 100 movesinto a dispensing mode (step 276). The dispensing port opens and themotor 124 reverses direction (step 278) to press the frozen confectionout of the pod 150. In some machines, however, the motor 124 does notreverse direction. The mixing paddle 160 is slowly rotated to allowfrozen material to form on the wall of the pod 150 while the evaporator108 gets cold. The RPM of the mixing paddle 160 is increased as thedecreasing temperature increases the rate at which frozen material formson the pod wall.

As previously described, in some machines the rotational speed of themixing paddle 160 increases to help air into the frozen confection toachieve improved overrun (preferably at least 30% overrun) and to helpgive enough velocity to extrude the ice cream out of the exit port ofthe pod 150 while achieving a constant flow (stream) of ice cream comingout of the pod.

Increasing the rotational velocity of the mixing paddle 160 increasesthe required electric current. The table below illustrates electricalcurrents of the current prototype machine that are used to drive themixing paddle 160 as a function of RPM and time into the freezingprocess (which affects the viscosity of the ice cream).

Seconds from start of the freezing cycle 3 15 30 45 60 75 90 105 RPM ofthe mixing paddle 275 275 275 315 435 558 800 1000 Current on the motorthat drive 372 658 1202 1833 2738 4491 9192 13719 the mixing paddle(milliamps)

Rotation of the mixing paddle 160 continues for approximately 1 to 10seconds to dispense the contents of the pod 150 (step 280). The machine100 then switches to defrost mode (step 282). Frost that builds up onthe evaporator 108 can reduce the heat transfer efficiency of theevaporator 108. In addition, the evaporator 108 can freeze to the pod150, the first portion 128 and second portion 130 of the evaporator canfreeze together, and/or the pod can freeze to the evaporator. Theevaporator can be defrosted between cycles to avoid these issues byopening the bypass valve 190, opening the evaporator 108, and turningoff the motor 124 (step 282). The machine then diverts gas through thebypass valve for about 1 to 10 seconds to defrost the evaporator (step284). The machine is programmed to defrost after every cycle, unless athermocouple reports that the evaporator 108 is already above freezing.The pod can then be removed. The machine 100 then returns to idle mode(step 264). In some machines, a thermometer measures the temperature ofthe contents of pod 150 and identifies when it is time to dispense thecontents of the pod. In some machines, the dispensing mode begins when apredetermined time is achieved. In some machines, a combination oftorque required to turn the mixing paddle, temperature of the pod,and/or time determines when it is time to dispense the contents of thepod.

If the idle time expires, the machine 100 automatically powers down(step 272). A user can also power down the machine 100 by holding downthe power button (286). When powering down, the processor opens thebypass valve 190 to equalize pressure across the valve (step 288). Themachine 100 waits ten seconds (step 290) then turns off the compressor186 and fans (step 292). The machine is then off.

FIGS. 16A-16C are detailed flow charts of an alternate method 1250implemented on the processor 122 for operating the machine 100. Themethod 1250 is similar to method 250. The method 1250 may be used withthe refrigeration systems and machines described in this specification.The method 1250 is described as producing soft serve ice cream but canalso be used to produce other cooled or frozen drinks and foods.

The first step of the method 1250 is to plug the machine 100 into anelectrical outlet (step 1252). Once an electrical connection isdetected, the processor 122 can initialize all variables. The processor122 and network hardware can search for software updates via WiFi orusing a wired Ethernet connection (step 1254). In some cases, cellularservice (such as 4G/5G LTE) is included in the machine 100 andconnection can be used for software updates and for pushingnotifications and alerts to user devices. Step 1252 occurs onceelectrical connection is detected and does not necessarily require themachine 100 to be turned on.

To verify proper functionality of the machine 100 prior to use, astart-up routine is performed once this electrical connection isdetected (step 1256). This process can identify issues or malfunctionswithin the machine and verify the machine 100 is ready for use. Theprocessor 122 proceeds to lock the lid to verify the lid lockingmechanism is working properly. This can be verified using sensors,including but not limited to limit switches, hall sensors,potentiometers, or any sensor that is capable of monitoring the positionof the lid and the functionality of the locking mechanism. During thistime, sensors in the machine 100 verify that the mixing motor isspinning properly. Sensors in the machine also verify the rivet shearingmechanism is in the home position, and if not, it is moved to the homeposition so that a pod can be inserted into the machine properly.Sensors in the machine 100 also verify that the piercing motor is in thehome position, and if not, it is moved to the home position (i.e.,retracted position) so that premature piercing of a pod is avoided.

The evaporator in the machine 100 is ensured to be in the closedposition, which can be monitored using electrical current being sent tothe motor closing the evaporator. When the evaporator is open, thecurrent applied to the motor is low, while when the evaporator isclosed, the current applied to the motor is large. This difference inelectrical current is be used to monitor the closure of the evaporator.A predetermined electrical current is be used as a threshold to monitorwhen the evaporator is open versus closed. The machine 100 is configuredto wait for the evaporator to close before continuing. Sensors in themachine also verify that the evaporator is in the open position when themachine is turned on (step 1258).

Machine 100 then waits for the evaporator to open, the piercing motor toretract (if not done already), and the rivet motor to return home (ifnot done already). The lid is also unlocked (step 1260). The machine 100then turns off or enters a low-power standby state until the machine isturned on (step 1262).

Once the machine 100 power button is pressed, the power button light isturned on (step 1264). The machine user interface includes a singlebutton with an LED ring. The single button acts as a power up, start,and power down button. In some machines, more than one button can beused. For example, a separate button is used for the power and ice creammaking process. At this point, the processor 122 instructs thecompressor and fan to turn on. The temperature of the inlet port to theevaporator is also regulated by the processor 122 to be about 33-40° F.via the bypass valve.

Once a pod (e.g., pod 150) is inserted into the machine and the lid isclosed (step 1265), the processor 122 of the machine 100 reads theidentification on the pod (step 1266). The identification is read invarious ways, such as a bar code, RFID tag, UPC bar, QR codes, or usingthe identification methods previously described. If no code is detectedthen the machine 100 goes back to step 1264 and allows the lid to beopened and closed again. The machine may also send an alert to a displayor user device notifying that the pod was not identified properly. Anaudible alert may also be used. Once the lid is closed again,identification of the pod is again attempted. Once the pod is identifiedproperly by the processor 122 and the barcode is detected, the machine100 proceeds to step 1268 where the processor 122 controls the buttonlight to blink as a notification to the user that the pod has beenidentified and that machine 100 is ready for use. The processor 122 mayalso send an alert to a display or user device of this notification. Anaudible alert may also be used.

If the lid opens, machine 100 reverts to step 1264 to reset machine 100and repeat the pod identification process (step 1266).

If the power button is held down or a predetermined time has elapsedwithout user interaction, e.g., the process times out, then theprocessor 122 of the machine 100 proceeds to open the bypass valve tobegin the shutdown process (step 1270). The bypass valve is openedimmediately before shutdown to equalize pressure between the high andlow sides of the refrigeration system quickly. This reduces the start-upload on the compressor if it is restarted shortly after being turnedoff. After waiting about 5 seconds, the processor 122 then proceeds toturn off the compressor and fan (step 1272) and the machine 100 isturned off (step 1262) where the machine 100 enters the low-powerstandby state.

FIG. 16B is a continuation of the method 1250. Once the start button ispressed, processor 122 proceeds to update the freezing parameters basedon information contained on pod (step 1274). In some cases, theinformation can identify temperatures, times, brand, flavor, contents ofpod, as well as mechanical aspects of the pod, for example, pressure ofthe pod, type of pod used, dimensions of the pod, mixing paddle designaspects, or rivet shearing design aspects. Pod data usage or datarelated to the pod and/or machine can be sent using the processor 122 toservers via WiFi or using a cellular network connection as previouslydescribed. This data can be used in identifying customers or frequencyof order placement for the pod subscription service. The lid of themachine 100 is also locked at this point the closed position so a usercannot inadvertently open the lid during the operation of the machine.The bypass valve the machine is also turned off.

The evaporator is closed to grip the pod (step 1276). As previouslydescribed, a predetermined target electrical current can be used by theprocessor 122 to identify the proper closed position of the evaporator.The evaporator can also be used to align a longitudinal axis of the podwith a longitudinal axis of the evaporator to ensure the pod is centeredin the evaporator. The evaporator must be closed before the piercingmotor punctures the can, so this ensures the can is centered before itis punctured.

The piercing motor is now controlled by the processor 122 to lower thedagger into the pod (step 1278). As described in this specification, insome pods, the dagger pierces the pod and then the dagger rotationallyengages with the mixing paddle. In some pods, the dagger does not needto pierce the pod.

Once the mixing motor is rotationally engaged with the pod, the mixingmotor is then controlled to turn on by the processor 122 (step 1280).Sensors on the machine 100 and connected to the processor 122 can ensurethat the mixing motor is operating properly and that no malfunctionshave been detected. The processor 122 commands the rotational speed ofthe mixing motor to gradually increase (ramp up) (step 1282). At thispoint, the processor 122 controls the mixing motor which spins themixing paddle inside the pod. The machine 100 is now in the process offreezing the ice cream and the processor 122 waits for this process tocomplete before continuing. As previously described, information can bedetermined from the information from the pod via a barcode. Informationcan be related to the freezing process, such as motor torque which canbe a proxy for measuring viscosity of the ice cream and freezing time.The machine 100 waits until the processor 122 detects that the ice creamis at the appropriate conditions for dispensing.

When the ice cream is ready to be dispensed, the user is notified by theprocessor 122 using a display on the machine 100, a notification to auser device, or using an audible alert. In some cases, the processor 122controls the power button light to blink three times (step 1284),however any number of blinks or lighting patterns can be used todistinguish this state of the ice cream making process from the poweredoff or powered on state. The rivet motor of the rivet shearing mechanismis then signaled by the processor 122 to being rotating.

FIG. 16C is a continuation of the method 1250. As the rivet mechanismengages with the rivet of the pod, the electrical current of the motorincreases dramatically. This increase in electrical current can be usedby the processor 122 to monitor and detect when the rivet shearingmechanism actually engages with the rivet of the pod during the shearingprocess. Upon continued rotation of the rivet motor, the rivet shearingmechanism causes the rivet of the pod to be removed from the pod (e.g.,the rivet can be mechanically sheared off). In some machines, the rivetor protrusion is moved out of the way instead of being sheared off orremoved (e.g., in reusable pods it is advantageous to have a reusablerivet). The processor 122 of the machine 100 ensures a spike in theelectrical current to the rivet motor occurs before continuing. Lack ofa spike of electrical current could be indicative of a machine 100malfunction.

After the rivet is sheared, the processor 122 controls the rivetshearing mechanism to turn a fixed distance to align the hole in thecutting cap attached to the pod with the port in the pod. This alignmentis required for dispensing the contents of the pod. Ice cream sill mixesas the rivet shears to prevent the auger from freezing to the pod. Therivet must shear and rotate 250° quickly, e.g., in under 2 seconds, toprevent ice cream from ejecting from the pod while the rivet is beingsheared (step 1286). Once the processor 122 of the machine 100 sensesthat the rivet has been removed, the rivet motor can be turned off (step1288).

The ice cream is now dispensed from the machine. It is usual for themixing motor to experience increased toque/load/current demands afternearly all the ice cream has been dispensed from the pod. This increasedtorque/load/current is caused because the evaporator is still chillingaggressively, but most of the mass has been evacuated from the pod. As aresult, the ice cream left in the pod gets very cold and can freeze themixing paddle to the pod. To reduce this effect, the bypass valve istimed to slightly warm the pod after nearly all ice cream has beendispensed (step 1290) which typically represents a wait time of seconds(500 ms) before opening the bypass valve, however this wait time can beadjusted based on information of the pod and machine 100 configurations.Note that when the bypass valve is opened, it can take several secondsfor the evaporator to begin warming up. Once this process is complete,typically after a wait time of 10 ms, the bypass valve is closed (step1292). The machine 100 then waits until all the ice cream is dispensedbefore continuing (step 1294).

During the dispensing process, the mixing motor is also ramped up inspeed (step 1295). The mixing motor is continued to rotate during thedispensing process, which can be about 4 to 12 seconds.

At this point, the machine 100 is ready to begin a reset process (step1296). First, the processor 122 commands the mixing motor to spin downand turn off. After the cooling cycle is complete and before the pod isremoved, the pod is chilled in the evaporator to just below freezing.Superficially, the evaporator inlet temperature is regulated, by theprocessor 122, to about 25-30° F. via the bypass valve. This temperatureprevents liquid from leaking from the pod when the bypass valve defroststhe evaporator from the pod, a necessary step before the evaporator isopened and the pod removed.

The processor 122 further commands the rivet motor to the home positionand commands the piercing motor to retract. The process waits until oneor more sensors detect that the rivet motor is in the home position andthe piercing motor is in the retracted position.

The processor 122 of the machine 100 commands the lid to unlock (step1297) so that a user can lift the lid and expose the top of the pod. Atthis point, the processor 122 regulates the evaporator inlet temperatureto about 33-40° F. via the bypass valve (step 1298). The processor 122can wait until the evaporator outlet temperature reaches at least 32° F.before continuing.

At this point, the processor 122 commands the evaporator to open so thatthe pod is released from the grip of the evaporator in anticipation ofremoval of the pod 150 from the receptacle of the machine 100. Theprocessor 122 may also allow the evaporator to stay open for apredetermined time (step 1299) during this process. The pod 150 is thenremoved from the machine 100 (step 1293).

The machine then reverts back to step 364 (as seen in FIG. 16A) wherethe processor 122 of the machine 100 configures the machine 100 to beready for the next pod to be inserted.

FIGS. 17A-17D are perspective views of a machine 300. The machine 300 issubstantially similar to the machine 100 but has a different mechanismfor opening the lid 112 to insert a pod 150 and to connect thedriveshaft of the machine 300 to the pod 150.

FIG. 17A show the machine 300 with the lid 112 in its closed position.In this position, a handle 302 is flush with the lid 112. FIG. 17B showsthe handle 302 raised to an intermediate position. In this position, thelid 112 stills covers the evaporator 108 but, as is explained in moredetail with respect to FIGS. 18A and 18B, the driveshaft 126 is raisedslightly.

The auxiliary cover 115 of the machine 300 slides back into the housing104 rather than pivoting like the auxiliary cover 115 of the machine100. FIG. 17C shows that, as the handle 302 is lifted further, thehandle 302 lifts the lid 112 to an open position with the auxiliarycover 115 starting to slide backwards under housing 104. FIG. 17D showsthe auxiliary cover 115 fully retracted into the housing 104 leavingspace for the handle 302 and the lid 112 to articulate far enough backthat a pod 150 can be inserted into the evaporator 108.

FIGS. 18A and 18B are partial cross-sectional views of the machine 300illustrating the insertion of a driveshaft 304 into the interior regionof the evaporator 108. The driveshaft 304 is attached to the handle 302.As shown in FIG. 18A, the driveshaft 304 is close to but spaced apartfrom the pod 150 when the handle 302 is in its intermediate position.Moving the handle 302 to its closed position forces the driveshaft 304through the second end of the pod 150 into engagement with an internalmixing paddle.

FIG. 19 is a partially-cutaway perspective view of the driveshaft 304.The driveshaft 304 includes teeth 306, a locking section 308, and aflange 310. The teeth 306 cut through the second end 212 of the pod 150(see FIG. 9C) when movement of the handle 302 to its closed positionforces the driveshaft 304 through the second end 212 of the pod 150. Insome systems, a sharp edge without teeth is used.

The locking section 308 is received in a bore in the mixing paddle 160.The bore in the mixing paddle 160 and locking section 308 of thedriveshaft 304 have matching shapes so rotation of the driveshaft 304causes rotation of the mixing paddle 160. The driveshaft 304 has alocking section 308 with a square cross-section. Some driveshafts havelocking sections with other shapes (e.g., hexagonal or octagonalcross-sections). The flange 310 of the driveshaft 304 is attached to thehandle 302. A central bore 312 extends through the driveshaft 304. Whenthe driveshaft 304 is inserted into a pod 150, the central bore 312 ofthe driveshaft 304 allows air to flow into the pod 150 as cooled food ordrink is being mixed and evacuating/dispensing out the other end of thepod 150. Some driveshafts are made of solid material.

In some machines, the driveshaft 304 is configured so that thepiercing/distal end of the driveshaft 304 is wider in diameter than thecentral portion of the driveshaft 304 so that the hole created in thealuminum pod is wider than the diameter of the central part ofdriveshaft 304. This configuration reduces the likelihood that thecentral portion of the driveshaft touches the pod while rotating. Inaddition, the driveshaft 304 may be coated with self-cleaning and/orhydrophobic coatings that reduce the amount of pod ingredients thatadhere to driveshaft 304. In some machines, the driveshaft 304 isrelieved so as not to hit the second end 212 of the pod 150 during thepuncturing process.

FIG. 20 is a perspective view of the dispenser 153 of the machine 300.The protrusions 163 of the annular member 161 are rectangular-shapedrather than dowel shaped. The dispenser 153 is otherwise substantiallythe same as the dispenser 153 of the machine 100.

Some machines implement other approaches to the pod-machine interfacethan the machine 100. For example, some machines have a pod-machineinterface that is movable relative to the body of the machine to exposethe receptacle defined by the evaporator. A loading system can controlthe position of the pod-machine interface relative to the body of themachine. In some of these machines, the lid is fixed in positionrelative to the body of the machine.

FIGS. 21A-21C illustrate a wedge system 400 associated with thepod-machine interface 350 that uses a lid 402 to clamp the evaporator352 around the pod 354. FIGS. 21A and 21B are, respectively, a schematicperspective view and a schematic side view of the pod-machine interface350 with the lid 402 spaced apart from the evaporator. FIG. 21C is aschematic side view of the pod-machine interface 350 engaged with thelid 402 in the closed position.

Each side of the evaporator 352 has a manifold 404 that connectschannels inside the walls of the evaporator 352 with the inlet ports 368and the outlet ports 369. The manifold 404 has sloped portions 406 nearthe inlet ports 368 and the outlet ports 369. The lid 402 has wedges 408on the side facing the evaporator 352. The wedges 408 have a flatsurface 410 and a sloped surface 412. When the pod-machine interface 350engaged with the lid 402 (e.g., by movement of a lid towards a fixedposition evaporator or by movement of an evaporator towards a fixedposition lid), the wedges 408 on the lid 402 contact the sloped portions406 of the manifold 404. The movement applies force to the slopedportions 406 of the manifold 404 on the evaporator and clamps a firstportion and a second portion of the evaporator 352 closed around a pod354 for a tight fit. Latching the lid 402 closed maintains this tightfit.

The loading mechanisms previously described receive a pod by insertingthe pod into the receptacle from the top of the pod-machine interface.Some machines load pods from the bottom of the pod-machine interface.

FIGS. 22A-22C show a driveshaft 540 with a barbed end 542 for engaging acomplementary recess 544 in a mixing paddle 546. The barbed end of thedriveshaft rotationally couples the driveshaft 540 to the mixing paddle.Driveshafts with a barbed end 542 may more easily pierce pods thandriveshafts with a square end.

FIG. 23 shows a perspective view of a machine 550 that is substantiallysimilar to the machine 300 shown in FIGS. 17A-17D. However, the machine550 has a handle 552 that is connected to a pinion 554 for moving adriveshaft up and down. The handle 552 is triangularly shaped and widensfrom a first end 556 to a second end 558. A dimple 560 on the first end556 of the handle 552 provides a gripping surface. The dimple 560indicates to the user where to grip the handle 552. Some handles haveother shapes (e.g., rectangular, square, or circular). Some handles areshaped like the handle shown in FIG. 17A (e.g., handle 302). A recess562 extends into the handle 552 from the second end 558 of the handle.The pinion 554 and an elevator shaft 564 are disposed in the recess 562.A user lifts the first end 556 of the handle 552 to rotate the handle552 about the second end 558 to open the lid 112. The user pressesdownwards on the first end 556 of the handle 552 to rotate the handle552 about the second end 558 and close the lid 112

FIGS. 24A-24E show a machine 600 with a handle 555 that operatessimilarly to the handle 302 on machine 300 in FIGS. 17A-17D. However, inFIGS. 24A-24E the handle 555 and the lid 112 rotate about the samehinge. The handle 555 is also larger and allowing a user to use theirentire hand to apply force to the driveshaft via the handle. The lengthof the handle 555 increases the mechanical advantage provided by thehandle 555 and decreases the required amount of force applied by theuser to puncture the pod and engage the driveshaft 304. The pod 150 asshown in FIG. 24B also includes a centering head 580 that engages withthe mixing paddle 160. The centering head 580 holds the mixing paddle160 in position with the central stem 228 along the rotational axis.FIGS. 24A and 24B show the handle 555 and lid 112 in its closedposition. The driveshaft 304 is extended into the evaporator to piercethe pod 150 and engage the mixing paddle 160. FIGS. 24C and 24D show thehandle 555 in the open position and the lid 112 in the closed position.The driveshaft 304 is retracted and is held within the lid 112. FIG. 24Eshows the lid 112 and the handle 555 in the open position. Theevaporator 108 is exposed and a pod 150 can be inserted into theevaporator 108.

FIGS. 25A-25C show a machine 650 with a spring-loaded handle 575,substantially similar to the handle 555. The spring-loaded handle isshown mounted to a machine 650 in a closed position in the top view ofFIG. 25A. A spring 576 provides a smooth transition of the handle 575 asthe driveshaft 304 is extended into the evaporator to pierce the pod 150and engage the mixing paddle 160. The spring 576 is connected to abearing housing 577 (best seen in FIG. 25C) and the handle 575. A cover585 extends over a second spring 579 (best seen in FIG. 25C), and theforce of the second spring 579 can ease raising/lowering of the handle575 on the machine 650. An auxiliary cover 583, which is substantiallysimilar to the auxiliary cover 115, is shown in a retracted position.

FIG. 25B is a perspective view of handle 575 mounted on machine 650 inthe closed position. The auxiliary cover 583 is shown in the closedposition. A pair of deflectors 581 and 582 engage the cover 585 of thehandle 575. The pair of deflectors 581 and 582 are mounted on theauxiliary cover 583.

FIG. 25C is a partially cutaway view showing a cross section of thehandle 575. A locating pin 578 sets the position of the spring 276. Thelocating pin is connected to the bearing housing 577. As the handle 575is lifted, the angle of the bearing changes to help the bearing slideforward and back without binding during lifting and closing. The springs276 assist the bearings on staying on track. The second spring 579 islocated in the rear of the bearing housing 577 and further provides asmooth transition of the handle 575. The handle 575 is connected to thecover 585 by mechanical fasteners, such as bolts (not shown).

FIGS. 26A-27B shows a machine 700 with a sliding lid assembly 701. Suchsliding lid assembly 701 can reduce the overall height of the machine700 relative to machines with lid assemblies that open upward. Thisapproach makes the machine 700 more compact and able to fit on kitchencountertops underneath cupboards.

Machine 700 is substantially similar to the machines previouslydiscussed (e.g., machine 650). However, the sliding lid assembly 701slides along tracks, or rails 707 and 708, to move from a closedconfiguration 705 (shown in FIGS. 26A and 26B) to an open configuration706 (shown in FIG. 26C). In the open configuration 706, the sliding lidassembly 701 translates rearward, along linear rails 707 and 708, toslide a cover 702 to reveal an opening 710 in the machine 700 foraccessing the pod 150. The user typically pushes/pulls the handle 715 totranslate the sliding lid assembly 701 from the closed configuration 705to the open configuration 706.

FIGS. 27A and 27B show a platform 714 of machine 700 which contains amotor to drive the paddle (the motor is not shown, but placed underneathplate 716 to drive the pulley 712 and belt 711) and a solenoid 713 todrive a driveshaft/plunger downward into the pod 150. (thedriveshaft/plunger is not shown). The pulley 712 mounted to a driveshaftof the motor and the motor is mounted to the plate 716. Since the motoris mechanically connected to the sliding lid assembly 701, the motoralso translates as the sliding lid assembly 701 translates from theclosed configuration 705 to the open configuration 706. The motor isrotationally coupled to the paddle through the pulley 712 and the belt711. The belt 711 is under tension both when the lid is in its openposition and when the lid is in its closed position. However, otherdrive mechanisms can also be used such as gear systems. The belt 711also translates with the sliding lid assembly 701 and a belt tensioningsystem can also be used (not shown). Once the sliding lid assembly 701is in the closed configuration 705 and ready to use, the solenoid 713 isused to engage the driveshaft and cause the driveshaft to plunge (notshown) downward into the pod 150. The driveshaft/plunger/dagger pokesthrough the domed end of the pod 150 and engages the hexagonal cavity ofa mixing paddle (such as mixing paddle 160) of the pod 150 (thesedetails were previously discussed and are not shown in FIGS. 27A and27B). The driveshaft is rotationally coupled to the belt 711 so themotor can rotationally drive the driveshaft once the driveshaft is matedto the paddle (not shown) in the pod 150.

FIGS. 28A-28D show a machine 650 that is substantially similar to themachines previously discussed (e.g., machine 600). However, in machine650 a solenoid 713 is not used to activate and engage thedriveshaft/plunger/dagger into the pod 150. Instead, a motor 750 isconnected to the driveshaft 755 using a rack 752 and pinion 751 systemto translate the driveshaft axially between a disengaged configuration760 and an engaged configuration 761. The motor 750 is orientedperpendicular to the driveshaft 755. The driveshaft 755 is substantiallysimilar to the previously described driveshafts except for the followingdifferences. A set of bearings 753 and 754 allow the driveshaft 755 torotate around a central axis 756. The driveshaft 755 is rotationallycoupled to a mixing motor (not shown) using a belt 757. The belt 757rotates a pulley 767 which is in an interference fit (typically apress-fit) with an intermediary member 766. A hexagonal bore 770 of theintermediary member 766 allows a keyed connection with a hexagonalsection 769 of the driveshaft 755. This keyed connection mechanicallycouples rotation of the pulley 767 to the driveshaft 755 so that thedriveshaft 755 is constrained from spinning with respect to the pulley767. The intermediary member 766 is rotationally connected to a bearing768 which allows it to freely rotate relative to the frame 758 and aframe 771.

The driveshaft 755 is axially secured using a shoulder 762 which matesagainst the bearing 754 and a snap ring 759 that mates against bearing753. The bearings 753 and 754 are secured in a housing 763. The housing763 axially translates between the disengaged configuration 760 and theengaged configuration 761 using the rack 752 and pinion 751 system whichaxially couples the motor 750 to the housing 763. The housing 763axially translates within a bore 765 of the frame 758. The mixing motor(not shown) spins the driveshaft 755 via the belt 757 and the motor 750,which is typically smaller and less powerful, translates the driveshaft755 axially via the rack 752 and pinion 751 system. The motor 750 isattached to the housing 763 via a motor mount 764.

In contrast to the previous machines, machine 650 does not require auser to manually operate a handle to punch the driveshaft (dagger)through a pod. In machine 650, this action is controlled by the motor750 and is automatically controlled by the machine 650. This providesadvantages where a user has difficulty manually operating a handle toapply the necessary piercing force. In some machines, an onboardcontroller monitors the axial position of the driveshaft 755 using anencoder on the motor 750 (not shown) and a limit switch (not shown). Forinstance, when the user inserts a pod (such as the pod 150) and hits thestart button, the evaporator closes and the driveshaft 755 plunges intothe pod 150, while potentially wiggling or rotating to ensure properalignment with an auger head of the paddle, and mixing and freezingwould commence.

FIG. 29A shows a cross section of a side view of an alternate driveshaft(dagger/plunger) assembly 800. Driveshaft assembly 800 is designed sothat a driveshaft 806 is lowered to pierce a pod with only the actuationof a mixing motor (not shown) through a pulley 801. Reversal of therotation of the mixing motor, and hence the pulley 801 fully retractsthe driveshaft 806.

The driveshaft assembly 800 uses the mixing motor (not shown) to drive apulley 801. The pulley 801 spins and engages with a first sprag bearing802. The first sprag bearing 802 is a one-way rotational bearing, orratchet system, that allows (i) an inside diameter of the bearing tospin relative to an outside diameter of the bearing in a firstrotational direction, and (ii) the inside diameter of the bearing torotationally lock relative to the outside diameter of the bearing in anopposite rotational direction. The first sprag bearing 802 connects toan intermediary piece 803 so when the first sprag bearing 802 spins in afirst rotational direction, the intermediary piece 803 rotationallylocks to the pulley 801, and slips in the other direction. Theintermediary piece 803 connects to a second sprag bearing 804. Thesecond sprag bearing 804 is orientated opposite the first sprag bearing802 so that the second sprag bearing 804 rotationally locks when thefirst sprag bearing 802 slips, and vice versa. The second sprag bearing804 is connected to a housing 805. Therefore, when spinning the mixingmotor in one direction (i.e., clockwise 821, also relative to anobserver looking in the direction 820), the intermediary piece 803 spinswith pulley 801; otherwise (i.e., counter-clockwise, or opposite of theclockwise direction 821), the intermediary piece 803 is fixed to thehousing 805.

The driveshaft 806 is left-hand threaded almost the entire length. Thethreads engage, at threaded interface 812, with internal threads insidea bore of the pulley 801. A detent pin, spring detent pin, or springdetent 807 is located, typically via press-fit, on top of the driveshaft806. When the mixing motor starts to spin clockwise 821, the pulley 801spins, and the driveshaft 806 also starts to spin. The spring detent 807of the driveshaft 806 spins in a groove 811 (best seen in FIG. 29B) ofthe housing 805 until the spring detent 807 engages, at interface 810,one of the protrusions 808 or 809 of the housing 805. Interface 810prevents further rotation of the driveshaft 806. Further clockwise 821rotation of the pulley 801 causes a translation of the driveshaft 806and begins threading, at threaded interface 812, into the bore of thepulley 801. Threading continues until the spring detent 807 engages withthe recess 813 of the intermediary piece 803 (best seen in FIG. 29D) andfurther engages with the shoulder 815. At this point, the spring detent807, and thus the driveshaft 806, begins rotating clockwise 821 with thepulley since the first and second sprag bearings 802, 804 are configuredso that the intermediary piece 803 spins with the pulley 801 during theactuation phase. The dagger 814 of the driveshaft 806 is now fullylowered to pierce a pod.

Upon reversal of the rotation of the mixing motor, i.e., in thecounter-clockwise direction 822, the driveshaft 806 retractsautomatically (i.e., no other motor or actuation method is necessary).During the retraction phase, the intermediary piece 803 is fixedrelative to the pulley 801 by the first and second sprag bearings 802,804. Once rotation is reversed, the spring detent 807 rotatescounter-clockwise 822 away from the shoulder 815 of the recess 813 ofthe intermediary piece 803. The recess 813 retract the spring detent 807at the small shoulder 816.

FIG. 30 shows the spring detent 807 engaging the small shoulder 816. Atthis point, further counter-clockwise 822 rotation of the pulley 801causes the driveshaft 806 to begin threading out of the bore of thepulley 801 and into the groove 811 of the housing 805. Furthercounter-clockwise rotation 822 continues to unscrew the driveshaft 806from the pulley 801 causing a reset of the driveshaft assembly 800. Thedriveshaft assembly 800 is now reset (fully retracted) and can be usedagain.

While clockwise 821 rotation of the pulley 801 engages the driveshaft806 and counter-clockwise 822 rotation disengages the pulley 801 in thismachine, some machines have mirrored versions of the driveshaft assembly800 where counter-clockwise rotation engages a driveshaft and clockwiserotation disengages the driveshaft.

FIG. 31 is a cross section of a perspective view of a machine 900, whichis substantially similar to the previous machines, except for theevaporator assembly. In machine 900, the evaporator 902 is mounted on aframe 903 and connected to a motor 901 that controls the opening andclosing of the evaporator 902. The motor 901 is mounted directly to theframe 903 permitting an in-line connection between the motor 901 and theopening/closing action of the evaporator 902. The motor system canprovide a compact system with reduced mechanical complexity.

FIGS. 32A and 32B show a perspective view and a partially cutawayperspective view of the evaporator assembly shown in FIG. 31,respectively. The evaporator 902 is biased in the open position by aspring 905. When the motor 901 is energized, it drives a nut 911 onto abolt 910 via a threaded connection. This threading action causes thespace between a left bracket 908 and a right bracket 909 (left and rightobserved relative to FIGS. 32A and 32B) to decrease. The torque of themotor 901 is connected to the nut 911 using a coupler 907. The coupler907 is sized to mate with the nut 911 via a hexagonal bore. The torqueof the motor 901 compresses the spring 905 and squeezes the evaporator902 closed. The bolts 904 and 906 provide hard limits to the closingaction so that a pod present in the evaporator is not crushed (a pod isnot shown in the evaporator 902). The ends of each respective bolt 904and 906 engage the right bracket 909 when the final closed position isreached providing this hard limit. Upon reversal of the motor, thespring 905 expands aiding in the opening of the evaporator 902 torelease the pod.

FIG. 33A is a schematic of a refrigeration system 930, which issubstantially similar to refrigeration system 109. The refrigerationsystem includes a condenser 180, a suction line heat exchanger 182, anexpansion device 184, and a compressor 186. High-pressure, liquidrefrigerant flows from the condenser 180 through the suction line heatexchanger 182 and the expansion device 184 to the evaporator 108. Theexpansion device 184 restricts the flow of the liquid refrigerant fluidand lowers the pressure of the liquid refrigerant as it leaves theexpansion device 184. The low-pressure liquid then moves to theevaporator 108 where heat is absorbed from a pod (such as pod 150) andits contents in the evaporator 108 changes the refrigerant from a liquidto a gas. The gas-phase refrigerant flows from the evaporator 108 to thecompressor 186 through the suction line heat exchanger 182. In thesuction line heat exchanger 182, the cold vapor leaving the evaporator108 pre-cools the liquid leaving the condenser 180. The refrigerantenters the compressor 186 as a low-pressure gas and leaves thecompressor 186 as a high-pressure gas. The gas then flows to thecondenser 180 where heat exchange cools and condenses the refrigerant toa liquid.

The second bypass line 190 enables the application of warm gas to theevaporator 108 to defrost the evaporator 108. The first bypass line 188directly connecting the discharge of the compressor 186 to the inlet ofthe compressor 186 can also be used but is not shown. The first andsecond bypass lines 188, 190 may be enabled and disabled using valves(such as solenoid valves or throttle valves—not shown).

Consumers expect a quality, frozen confection on the first cycle withoutwaiting several minutes for the machine to warm-up. Refrigerationsystems with capillary tube heat exchangers 182 (e.g., refrigerationsystem 109) are not actively controlled and can take longer thanactively-controlled systems (e.g., systems using thermal expansiondevices or valves) to reach steady state. When the machine is initiallyturned on, the warm-up process enters “hot gas bypass mode,” whichcycles a solenoid to control the evaporator 108 temperature to belowambient conditions.

A risk in starting the machine in standard cooling mode versus hot gasbypass mode is that without a pod or heat load in the evaporator, therefrigerant would not be fully vaporized before returning to thecompressor 186, risking compressor damage by attempting to compress anincompressible liquid. Another limitation of the hot gas bypass approachis that while the system is somewhat “warmed-up” after several minutes,it is not at the actual temperatures it would experience under coolingconditions. In addition, during bypass mode the capillary tube orifice182 is receiving a constantly varying flow rate, which is different fromthe flow during cooling mode.

When a pod (e.g., pod 150) is inserted into the evaporator 108, and thecooling process is started, the temperatures and refrigerant flow rateswill need time to adjust from the hot gas bypass mode conditions to thecooling conditions. This delay will increase the time to cool theproduct versus if the pod was placed in an evaporator in cooling mode.However starting a refrigeration process in cooling mode without a heatload risks damaging the compressor.

Refrigeration system 930 goes directly into a cooling mode as a solutionto the delay where the temperatures and refrigerant flow rates need timeto adjust from the hot gas bypass mode conditions to the coolingconditions. An electrical heater 931 located either before or after theevaporator 108 provides a heat load on start-up to simulate cooling icecream. The heater vaporizes refrigerant, similar to how liquid ice creammix in the pod would affect the refrigerant system 930, allowing therefrigerant system 930 to achieve steady state cooling conditions forrefrigerant temperature, pressure and flow rates without the need for anice cream pod placed in the machine. From an ambient (room temperature)start, the machine will reach steady state faster than refrigerationsystem 109 and does not risk damaging the compressor. While notillustrated in FIG. 33A, a first bypass line 188 or valve (as seen inFIG. 6) can also be used in the refrigeration system 930.

FIG. 33B shows a refrigeration system 940 using a thermal battery 941.The thermal battery 941 provides a thermal “capacitance” or “reservoir”to remove some cooling load from the vapor compression system, therebyreducing the freezing time. When the machine is starting from roomtemperature, valves 942 and 943 (e.g., solenoid valves or throttlevalves) are open and the thermal battery 941 does not receiverefrigerant. Towards the end or at the end of the first cooling cycle,valve 943 closes and cold refrigerant flows to the thermal battery 941.When the cold refrigerant flows to the thermal battery 941, paraffininside the thermal battery 941 is solidified. Pre-cooling the thermalbattery at the end of one cycle will allow the thermal battery 941 to beused to reduce the cooling load on the compressor 186 during the nextcooling cycle. The energy required to solidify a material is largecompared to the energy required to lower its temperature.

Wax is used in the thermal battery 941. Many waxes solidify at aconvenient temperature for use in the thermal battery 941. Some waxes(e.g., alkanes) have a melting point in a range of 5° C.-10° C. Forexample, Dodecane wax or Tridecane wax have melting points in thisrange. These waxes are used in the thermal battery 941 because theysolidify at a temperature that is between the hot side and cold sidetemperatures of the refrigeration system 940 and can store thermal“capacitance” and transfer or use that capacitance on subsequent coolingcycles. Energy is removed from the wax during a time when the machine isnot in a cooling mode, or at least when the user is not expecting themachine to be cooling. Cooling the thermal battery 941 has theadditional benefit of heating up refrigerant which protects thecompressor 186 from liquid refrigerant which could result in damage tothe compressor 186. During the second cooling cycle, valve 942 is closedsending hot liquid refrigerant to the thermal battery 941, whichpre-cools the thermal battery 941 before the refrigerant reaches theexpansion device 184. During this same cycle valve 943 is open allowingcold refrigerant to bypass the battery. At the end of the second cyclevalve 943 closes and valve 942 opens, cooling the thermal battery 941for the next cycle. This process repeats allowing the cooling from theend of one cycle to be used or “stored” for use on the next cycle, whichcan reduce the required freezing time.

FIGS. 34A-34D shows a mixing paddle which is substantially similar tothe mixing paddle 160, except it is partly over-molded with a polymer tosqueegee frozen ice cream from the inside of the pod (e.g., pod 150). InFIG. 34A, an aluminum paddle 951 is formed (typically stamped andbent/twisted, but can be formed in other ways such as cast, forged, ormachined). Ribs 960 on the top region 952 of the aluminum paddle 951give extra stiffness to the thin areas of the aluminum paddle 951. Thisextra stiffness is important since the thin areas of the aluminum paddle951 are subject to large torques from the drive head during the mixingprocess and reduces deformation of the aluminum paddle 951 under thisapplied torque. Edge molds 958 and 959 are molded (i.e., poured andcast) in place over each edge 954 and 955, respectively. This process isoften referred to as “over-molding,” and can create a part with multiplematerials.

Other molding techniques can be used, such as molding the edge molds 958and 959 separately and then inserting or mating the aluminum paddle 951with the edge molds 958 and 959. These over-moldings 956-959 can helpsqueegee a frozen ice cream buildup from an inner diameter of a pod wall(e.g., pod wall 214) and the bottom of the pod (e.g., first end 210). Atop cap 956 of silicone can be molded in place over a top region 952 ofthe aluminum paddle 951 and a bottom cap 957 of silicone can be moldedin place over a bottom region 953 of the aluminum paddle 951. The mixingpaddle 950 is formed once the over-molds are complete. The top cap 956can be over-molded to include the drive head 961 of the mixing paddle950 as well. FIGS. 34C and 34D are top and bottom views of mixing paddle950, respectively.

In some cases, dip coating of plastic is used to coat the aluminumpaddle 951 to prevent the metal mixing paddle 951 from rotating on themetal lid (e.g., first end 210) and pod walls (e.g., pod wall 214). Insome cases, a polyolefin coating is used. Typical properties of thepolyolefin coating are represented in the following table:

Properties Test Methods Value Color N/A As required Abrasion (H18, 500 gASTM D 4060/84 69 mg weight loss load, 1000 cycles) Hardness Shore A 98Hardness Shore D 58 Tensile Strength ISO 527 (4 in/mm) 2320 lbs/in²Elongation at Break ISO 527 160% Dielectric Strength ASTM D-149 >700volts/mil Salt Stray (500 hours) ASTM B-117 <15 mm from scribe StressCracking ASTM D 1693 >1000 Hours Vicat Softening Point ISO 306 266degrees F. Melting Point N/A 311 degrees F.

FIGS. 35A-35D also show a pair of notches 962. Notches 962 are sizedsuch that they fit over a lip 971 on the inside of a second end of a pod(such as the first end 210 of the 150). Although shown on mixing paddle951, other mixing paddles (e.g., the mixing paddle 950 or the mixingpaddle 160) can also include such notches. Once installed, contact 972allows the mixing paddle 951 to rotate along the lip or track 971 insidethe pod 150 to help guide the mixing paddle 951 and provide structuralsupport to the mixing paddle 951.

FIGS. 36A and 36B shows a mixing paddle 1550 which is substantiallysimilar to the mixing paddle 951, except notches 1551 of the mixingpaddle 1550 avoid direct contact with the lip 971 of the pod 150. Thepod 150 includes the cap 166. The notches 1551 are sized to allow apolymer liner 1552 or bushing to be used between the lip 971 of the pod150 and the notches 1551 of the mixing paddle 1550. The polymer liner1552 is used to lower the friction between the notches 1551 and the lip971.

The polymer liner 1552 is shaped as a ring and functions as a bushing toreduce friction between the rotating mixing paddle 951 and the metal lip971 of the pod 150. By reducing friction, galling and wear of thematerials of the mixing paddle 971 and the lip 971 is reduced. Thepolymer liner 1552 also reduces heat in the pod when the rotating mixingpaddle spins when making frozen confections in the machine. The polymerliner 1552 include a receptacle that engages with the lip 971. Thepolymer liner 1552 is radially constrained to the lip 971. The polymerliner 1550 includes a flat upper surface 1553 that contacts a lowersurface of the notches 1551 of the mixing paddle 1550. The polymer liner1550 includes a radial inner surface 1554 that contacts a radial outersurface of the notches 1551 of the mixing paddle 1550.

FIG. 37A shows a cross-section of a perspective view of a first end 981of a pod—substantially similar to the first end 210 of the pod 150 butwhich includes an over-molded connection for receiving the driveshaft. Asilicone sealing grommet 980 is over-molded between the first end 981and a plastic plug or paddle driver 982. The over-molding causes acovalent bond creating a hermetic seal between the grommet 980 and thepaddle driver 982. A head 983 sticks out of the first end 981 forengagement with the driveshaft of a mixing motor (not shown). The headis keyed to provide a rotationally locked connection with thedriveshaft. By providing a sealed connection, this approach avoids theneed for the driveshaft to pierce the pod, therefore using the gasstored within the pod (typically Nitrogen) to assist in developingoverrun or loft. In some cases, when the driveshaft rotates the paddledriver 982, the covalent bond between the mixing paddle 950 and thegrommet 980 breaks allowing the shaft to rotate and air to flow into thepod for producing overrun. In another approach, a grommet 985 can beglued against a plastic plug or paddle driver 986. FIG. 37B illustratesthe grommet 985 sliding 988 over a shaft 987 and glued into place on thepaddle drive 986. Various other examples of grommets or sealing piecescan be used such as grommets 991 or lip seals 992 (or rotary seals) asshown in FIGS. 37C and 37D, respectively.

FIGS. 38A-38D are perspective views of a mixing paddle 1350 of a pod 150with integral dog ears 1354 and a mating drive head 1352 that forms amating drive assembly 1355. Assembly 1355 rotationally couples thedagger/driveshaft of the ice cream machine to the mixing paddle 1350 andhelps avoid undesirable deformation, buckling, or bending when thetorque of the machine is large. In assembly 1355, the mixing paddle 1350is stamped or formed using sheet metal and one or more dog ears 1354 areformed by bending the sheet metal onto an end of the mixing paddle 1350.The mixing paddle 135 can be made of aluminum, approximately 0.032inches thick, and then subsequently bent in a sheet metalpress/dye/machine to form dog ears 1354 on the mixing paddle 1350. Thedog ears 1354 can give the mixing paddle 1350 increased stiffness andtorsional rigidity compared to mechanical stiffeners such as ribs. Somemixing paddles include dog ears 1354 in addition to ribs.

To transfer the torque, inner surfaces 1360 of the dog ears 1354 matewith corresponding surfaces of a mating drive head 1352 that can be seenin the translucent perspective view of FIG. 38A, and seen in furtherdetail in FIGS. 38C and 38D.

The mating drive head 1352 receives the dagger/driveshaft (not shown inFIGS. 38A-38D) from the ice cream machine and rotationally couple thedagger/driveshaft to the mixing paddle. Mating drive head 1352 istypically constructed out of aluminum, metal, or a hard plastic.

As previously described, pod 150 is originally hermetically sealed. Asthe dagger/driveshaft lowered into the domed region 1362 of the pod 150,it pierces the pod 150 and is received by the receptacle 1358 of themating drive head 1352.

Referring to FIG. 38C, mating drive head 1352 can be slidably connectedwith the mixing paddle 1350 by a friction fit. By manufacturing adiameter or width of the mating drive head 1352 to have a slightlylarger spacing between the inner surfaces 1360, 1364 of the dog ears1354, a slight interference, or friction fit can be achieved whenassembling the mating drive head 1352 to the mixing paddle 1350. Detentsor other latches can be incorporated into either the mixing paddle 1350or the mating drive head 1352 in order to retain the mixing paddle 1350to the mating drive head 1352 and ensure proper rotational coupling. Themating drive head 1352 can be snapped into place. The mating drive head1352 can also be releasable connected to the mixing paddle 1350.

The dog ears 1354 of the mixing paddle 1350 can be designed to permitonly one-way rotational coupling. For example, in FIGS. 38A-38D, aclockwise rotation of the driveshaft would be rotationally coupled tothe mixing paddle 1350, but counter-clockwise rotation could be releasedby the anti-symmetric design of the dog ears 1354.

In operation, the domed region 1362 of the pod 150 is pierced, thedagger/driveshaft engages with the receptacle 1358 of the mating drivehead 1352, and the driveshaft can quickly spin to mix the ice cream,produce overrun, and dispense the ice cream.

Pods 150 are typically filled then retorted or can be asepticallyfilled. In either case they are backfilled with Nitrogen so air does notget into the pod 150 prematurely. This is typically referred to as‘headspace.’ However, during the ice cream mixing process, it isdesirable to introduce air into the mixing process to produce overrun.In some machines, the pods do not need to introduce air and can rely onthe nitrogen in the pod. In these cases the pod can remain sealed duringat least part of the mixing process. In some cases, air can beintroduced during the mixing process.

FIGS. 39A-39B are perspective views of the mixing paddle 1350 of a pod150 that engages with a mating drive head 1370 to form a mating driveassembly 1365. The functionality of the mating drive head 1370 issimilar to the mating drive head 1352 by rotationally coupling thedriveshaft of the machine to the mixing paddle 1350, but differentbecause the pod 150 is never pierced by the driveshaft when mating driveassembly 1365 is used.

Mating drive head 1370 includes a receptacle 1378 that receives a shaft1382 of a grommet 1380 to rotationally couple the driveshaft 1374 to themixing paddle 1350. The rotational connection and engagement betweenmating drive head 1370 and the mixing paddle 1350 is similar to theconnection of mating drive head 1352 (i.e., a rotationally keyedconnection). Mating drive head 1370 can also be connected using aninterference fit (a press fit), snapped, latched, or otherwisemechanically fastened similarly to mating drive head 1352.

Grommet 1380 includes a receptacle 1372 that receives a driveshaft 1374that can be similar to any of the driveshaft's described in thisspecification, except the driveshaft 1374 can be formed with a bluntedend 1376 since the driveshaft 1374 does not need to piece the pod 150 atall. Instead, a hole in the domed portion of the pod 150 is made duringfilling and assembly of the pod, and the pod remains hermetically sealedduring storage. Grommet 1380 includes an o-ring 1384 that is used toprovide this sealed connection of the contents of the pod 150. Whileonly one o-ring 1384 is shown, multiple o-rings can be used.

Exterior threads 1386 on a cylindrical outer surface of the grommet 1380is configured to threadably engage with corresponding internal threads1388 of a seal member 1390. During installation, the grommet 1380 isinstalled from the interior of the pod 150 with the receptacle 1372 andexterior threads 1386 sticking out of the pod 150. The seal member 1390is threaded tightly onto the exterior threads 1386 of grommet 1380 andalso adhered to the surface of the domed portion of the pod 150. Thisforms both an air-tight seal between of the pod 150 and also allows thegrommet 1380 to rotate relative to the seal member 1390.

The seal member 1390 is adhered to the pod so it cannot move. Adheringthe seal member 1390 can be performed with glue, rivets, or any processthat would hold the seal member 1390 in place. During operation, thedriveshaft 1374 lowers into the receptacle 1372 of the grommet 1380 andbegins to rotate. As the driveshaft 1374 begins to rotate, the exteriorthreads 1386 begin to unscrew from the interior threads of the sealmember 1390. This causes the grommet 1380 to lower itself into the pod150. This lowering motion causes the shaft 1382 of the grommet 1380 tolower into the receptacle 1378 of the mating drive head 1370. Thedimensions of the shaft 1382 and receptacle 1378 can be sized such thatrotational coupling between the driveshaft 1374 and the mixing paddle1350 only occurs once the grommet 1380 is lowered into the pod 150 bythe driveshaft 1374, or it can be sized such that it is alwaysrotationally coupled.

Once the grommet 1380 clears the mating threads of the seal member 1390it is free to rotate without further vertical translation. For example,the cylindrical surface 1392 of the grommet 1380 could freely spinwithin the threads of the seal member 1390. This means that thedriveshaft 1374 can continue to spin to rotationally engage the mixingpaddle 1350 long after the grommet 1380 moves downward and the grommet1380 completely unscrews itself from the seal member 1390. The shaft1382 of the grommet would further slide into the receptacle 1378 and theshaft 1382 can be configured to bottom out in the receptacle 1378 tomaximize the strength of the rotational connection between the grommet1380 and the mating drive head 1370.

The grommet 1380 can also be configured to break the seal of the pod 150upon lowering into the pod 150 caused by rotation. Once the seal isbroken, air can enter the pod 150 to aid in the mixing of the ice creamand the production of overrun. The threaded engagement 1386 anddimensions of the shafts 1374, 1382 and receptacles 1372, 1378 can besized to minimize or maximize the air intake during the mixing process.For example, in cases where no air is desired at all, the pod 150 canremain sealed by using a very small thread pitch on the grommet 1380, ora rotating seal could be used to eliminate the thread pitch altogether.In this way, the driveshaft 1374 could rotate indefinitely and the sealwould not be broken. In other cases where maximum air intake is desiredas quickly as possible, the grommet 1380 can have a very large threadpitch so that the seal is broken with less than one revolution of thedriveshaft 1374.

Another advantage of mating drive assembly 1365 is that the driveshaft1374 never enters the pod 150. This means it does not get contaminatedby dairy and hence require washing. Furthermore, since the pod 150 doesnot need to be pierced, the likelihood of aluminum shards entering thecan is significantly reduced or eliminated.

The grommet 1380 is typically constructed out of aluminum, metal, orhard plastic so that it can withstand the required torques during theice cream making process. A hard durometer elastomer could also be usedwhich would help seal the pod 150. The seal member 1390 can be made ofthese materials as well and the o-ring 1384 is typically elastomeric.

FIGS. 40A-40C are plan and perspective views of the mixing paddle 1350of a pod 150 to form a mating drive assembly 1600. Mating drive assembly1600 is substantially similar to mating drive assembly 1365 seen inFIGS. 39A-39B, except the functionality of the grommet 1380 and themating drive head 1370 is combined into a single component. This singlecomponent is the mating drive head 1602.

The mixing paddle 1350 is rotationally coupled to the mating drive head1602 through a connection 1614 (best seen in FIG. 40C). The connection1614 is preferably a welded connection, but other connections can beused. In some cases, the connection 1614 is a friction connection thatis formed by engaging one or more grooves 1616 of the mating drive head1602 onto complementary one or more edges of the mixing paddle 1350. Insome cases, the connection 1614 is engaged by rotating the mating drivehead 1602 relative to the mixing paddle 1350 90 degrees. In some cases,the connection 1614 is formed during the manufacturing process when themating drive head 1602 is molded in the assembled position on the mixingpaddle 1350 as shown in FIGS. 40A-40C. In some cases, the connection1614 is adhered (e.g., glued). In some cases, the mechanical coupling ismade with a fastener (e.g., a set screw).

A seal member 1604, which is substantially similar to seal member 1390,is adhered to the pod so it cannot move. Adhering the seal member 1604can be performed with glue, rivets, or any process that would hold theseal member 1604 in place. The seal member 1604 is shown on the outersurface of the pod 150, but in some pods, is on the interior of the pod.In some pods, the seal member 1604 spans the interior of the pod 150 tothe exterior of the pod 150.

Exterior threads 1606 on a cylindrical outer surface of the mating drivehead 1602 is configured to threadably engage with corresponding internalthreads 1608 of the seal member 1604. During operation, the driveshaft(not shown in FIGS. 40A-40C) of the machine lowers into the receptacle1610 of the mating drive head 1602. The receptacle 1610 is keyed (bestseen in FIG. 40B) so that rotation is between the driveshaft and themating drive head 1602 is coupled. As the driveshaft begins to rotate,the exterior threads 1606 begin to unscrew from the interior threads ofthe seal member 1604. This causes the mating drive head 1602 to loweritself into the pod 150. This lowering motion causes the mixing paddle1350 to lower into the pod 150 as well, but the amount of lowering ispreferably small by the using a small thread pitch of the threadedconnection between the mating drive head 1602 and the seal member 1604.Once the external threads 1606 of the mating drive head 1602 lowers pastthe lower edge of the internal threads 1608 of the seal member 1604, thethreaded connection disengages and the mating drive head 1602 (and themixing paddle 1350) can freely spin within the pod 150 and the bottom ofthe mixing paddle 1350 lowers onto the lip 971 of the pod 150 (not shownin FIGS. 40A-40C). At this point during operation, the mixing paddle1350 can spin under the control of the mixing motor of the machine

The threaded connection between the exterior threads 1606 and theinterior threads 1608 is reversible if the rotation of the mixing motoris reversed. This allows the machine to reseal the pod 150.

The mating drive head 1602 also includes a cylindrical section 1620 thatis configured to center the mating drive head 1602 and the mixing paddle1350 in the pod 150 after the threaded connection between the exteriorthreads 1606 and the interior threads 1608 have disengaged. An outerdiameter of the cylindrical section 1620 is slightly less than theinternal diameter of the interior threads 1608 so that a rotationalclearance is allowed but centering of the mixing paddle 1350 in the pod150 is also possible.

The mating drive head 1602 also functions to seal the pod 150. Beforethe mating drive head 102 is lowered into the position shown in FIG.40A, an o-ring (not shown in FIGS. 40A-40C) which is located in a groove1612 is pressed against the inside dome of the pod 150 forming a seal.This seal is complemented by the threaded connection between exteriorthreads 1606 and the interior threads 1608. These seals help to sealoutside air from getting into the pod 150 so the pod 150 can remainhermetically sealed until it is ready for use in the machine.

FIGS. 41A-41F are perspective views of the mixing paddle 1350 thatengages with an mating drive head 1402 to form a mating drive assembly1400. In mating drive assembly 1400, the pod 150 is pierced by adagger/driveshaft 1406, but the dagger/driveshaft 1406 does not contactthe contents of the pod 150 and any shards of aluminum resulting fromthe piercing action are captured in the space 1408 which is sealed fromthe contents of the pod 150. The dagger/driveshaft 1406 is rotationallycoupled to the mixing paddle 1350 once the dagger head 1410 slides intothe receptacle 1412 of the mating drive head 1402. Rotational engagementbetween the mating drive head 1402 and the mixing paddle 1350 is similarto the mating drive heads 1352, 1370.

A guide bushing 1404 is adhered or glued to the inside of the domedregion of the pod 150. The mating drive head 1402 includes a cylindricalprotrusion 1416 that includes a recess for an o-ring 1414. The o-ring1414 hermetically seals the mating drive head 1402 to the guide bushing1404. The dagger/driveshaft 1406 punctures through the domed region ofthe pod 150 and rotates the mating drive head 1402 and the mixing paddle1350. The o-ring 1414 may be a dynamic o-ring since the mating drivehead 1402 will rotate relative to the guide bushing 1404. The protrusion1416 of the mating drive head 1402 may be chamfered to provide a lead-inangle for ease of assembling the mating drive head 1402 into the bore ofthe guide bushing 1404. The mating drive head 1402 or the guide bushing1404 may be aluminum, metal, hard plastic, or a high durometer elastomerto support the torques required during mixing, scraping, and dispensingof the ice cream.

Mating drive assembly 1400 allows a pod 150 to be hermetically sealedduring packaging. This seal continues to be intact even after piercingby the dagger/driveshaft 1406. This means that air does not enter thepod 150 during the mixing process which is typically used to aid in thegeneration of overrun. However, in this case, Nitrogen of the pod canassist in the development of overrun, and/or micro pores in cylindricalprotrusion 1416 can be used to allow air to enter the pod 150 for thispurpose.

FIGS. 42A-42D are perspective views of the mixing paddle 1350 thatengages with a mating drive head 1420 to form a mating drive assembly1425. Mating drive assembly 1425 is different from mating driveassemblies 1355, 1365, 1400 in that only one part, namely mating drivehead 1420, is needed to form the rotary coupling and the sealedconnection.

Mating drive head 1420 is molded from an elastomer or a hard plastic andis configured to rotatably deform and break at a weakened region 1422when torque is applied to the hex surface 1424. Hex surface 1424 isconfigured to slidably engage with a driveshaft of the machine (notshown). Large cylindrical bearing surfaces 1426 are configured to adhereto the domed region of the pod 150 by gluing or otherwise permanentfastening.

Weakened region 1422 may be cylindrical. Weakened region 1422 may alsobe broken by a vertical displacement of the driveshaft onto the hexsurface 1424 to cause the entire central region of the mating drive head1420 to move downward. Sometimes both vertical displacement and rotationcan cause the weakened region 1422 to break.

Torque is transferred from the mating drive head 1420 to the mixingpaddle 1350 similarly to mating drive heads 1352, 1370, 1402. Forexample, clockwise rotation of the mating drive head 1420 causes amechanical connection, via compression, at location 1428 on the surfaceof the dog ears 1354 of the mixing paddle 1350 to transfer the torqueand rotationally couple the driveshaft of the machine to the mixingpaddle 1350.

Mating drive head 1420 is hermetically sealed during packaging and theseal is configured to break during the ice cream mixing process to allowair to enter the pod 150 to generate overrun.

FIGS. 43A-43C show a mixing paddle 1000 with windows 1001-1004 that areoff-center (or eccentric) relative to a drive axis 1006. Windows 1001and 1002 are cut such that center sections 1007 and 1008 are radiallybiased to alternate sides of the mixing paddle 1000. Windows 1001 and1002 do not need to be alternating but this configuration is helpful forrotationally balancing. A mixing paddle 1000 with windows 1001 and 1002will mix the frozen confection better than a mixing paddle with balancedwindows with center sections that simply rotate in the center of the podbecause windows 1001 and 1002 can swing around the drive axis 1006 toact like a mixing stick, or beater, and help to mix the frozenconfection. Mixing paddle 1000, in similarity to the previouslymentioned mixing paddles, is also helically shaped to drive the frozenconfection downward to facilitate top to bottom mixing and drive thefrozen confection out of a pod. This driving action is similar to ascrew conveyer. The mixing paddle 1000 mixes product laterally and pullsin air to create loft. The mixing paddle 1000 also features one or moreteeth 1004 that helps to break up frozen product and scrape product offof the wall of the pod into smaller pieces or streams. This paddle hasfour teeth, but there is no upper limit to the number of teeth.

Some mixing paddles include ribs or other features to increase torsionalresistance. Some mixing paddles exhibit high torsional rigidity (e.g.,greater than 15 ozf-in) and a high torque to failure limit (e.g.,greater than 150 ozf-in). Some mixing paddles have a low surfaceroughness (e.g., less than 8-16 Ra) to prevent product from sticking tothe mixing paddle and to help remove product that sticks to the mixingpaddle. With mixing paddles having a surface roughness between 8-16 Ra,these machines evacuate at least 85% of the frozen confection in the podand usually 95%. Some mixing paddles have a recess at the second end ofthe mixing paddle, allowing the mixing paddle to be turned to the centeraxis of the mixing paddle. During manufacturing, the twist of the mixingpaddle at the bottom can be very large 100° to 150° which can be aproblem for the stamping process which can tear the material of themixing paddle. A cut notch (not shown) in the center of the bottom ofthe mixing paddle blades enables the mixing paddle to be formed withouttearing the material.

As previously described, the cap 166 of a pod 150 includes a protrusion165 that is sheared off to allow the dispensing of product from the pod(e.g., see FIGS. 10A and 11A-11G). The cap 166 is mounted over base 162and is rotatable around the circumference/axis of the pod 150. In use,when the product is ready to be dispensed from the pod 150, thedispenser 153 of the machine engages and rotates the cap 166 around thefirst end of the pod 150. Cap 166 is rotated to a position to engage andthen separate the protrusion 165 from the rest of the base 162. However,some systems incorporate the shearing mechanism as part of the machinerather than as part of the pod.

FIGS. 44A-44B show cross sections of a perspective view of a machine1100 with a protrusion shearing mechanism 1050 that engages and shearsoff the protrusion 165 from the base 162. The protrusion shearingmechanism 1050 does not require the cap to be rotationally aligned ororiented in any particular direction with respect to the evaporator 108(not shown). For example, the pod 150 can be inserted into theevaporator without a user having to rotationally align the pod with theprotrusion shearing mechanism 1050. The machine will accept the pod 150with any angular orientation.

FIGS. 45A-45E show a cam 1051 pivotally connected to a gear 1052 whichis rotated by a shearing motor 1054. In operation, the cam 1051 isrotated out of the way by the back side of the cam 1051 riding along thehome dog 1057 (i.e., “home position”). Once the pod 150 with cap 166 isinserted into the opening 1058 of a frame 1053, a spring 1055 provides aforce pressing the cam 1051 onto the cap 166 of the pod 150. The frame1053 is mounted to a housing 1059 as part of the machine 1100 and isfixed in position.

Once the gear 1052 is rotated, the cam 1051 is forced further intocontact with the cap 166 and a firm grip is generated by the cam 1051being wedged between the rotating gear 1052 and the cap 166. A knurledsurface 1056 of the cam 1051 helps to provide this firm grip and refrainthe cap 166 from rotating relative to the gear 1052. As the gear 1052 isrotated, the cam 1051 travels off the home dog 1057 (i.e., “engagingposition”). Rotation of the gear 1052 ultimately turns the shearing capwhich shears the protrusion 165 and opens the pod aperture.

FIG. 46 is a cross section of a perspective view of the machine 1100illustrating the engagement 1063 of the cap 166 with the gear 1052. Abearing 1062 allows the gear 1052 to spin relative to the machine 1100and a snap ring or retaining ring 1061 axially secures the gear 1052 inplace.

In some machines, the mixing paddle never stops rotating during theshearing of the protrusion. In some machines, during the protrusionshearing process, rotation of the cap 166 of the pod 150 is opposite thedirection of the rotation of the mixing paddle 160. By rotating inopposite directions, the likelihood of the pod 150 slipping in theevaporator 108 is reduced. This is shown in FIGS. 47A and 47B.

FIG. 47A shows cap shearing system 1120 that is a subassembly of amachine. The cap shearing system 1120 features a protrusion shearingprocess that is preformed clockwise 1110 (i.e., clockwise relative to adirection 1105 looking down the pod 150) and the mixing paddle 160 thatis rotated clockwise as well. In contrast, FIG. 47B shows a cap shearingsystem 1125 where cap 166 enables the protrusion 165 to be sheared in acounter-clockwise direction 1111 (counter-clockwise relative to adirection 1105 looking down the pod 150). The cap 1101 has a firstaperture 1102 and a second aperture 1103 that mirrors the first aperture222 and second aperture 224 of the cap 166.

By rotating the shearing cap 166 in the opposite direction of the mixingpaddle 160, the rotational or torsional forces cancel out allowing theclamshell evaporator 108 to close with enough force to keep the pod 150from slipping/rotating in the clamped evaporator 108. This is importantso the first aperture (222 and 1102) on the cap (166 and 1101) properlyalign with the protrusion opening 165. If the pod 150 slips relative tothe cap (166 and 1101), the first aperture may not align, and thefunctionality of the machine will be affected.

Some pods can include a first end that is removable and a reusablemixing paddle may be inserted into the first end. The mixing paddle maybe removed, washed, and reused for subsequent use.

FIGS. 48A-48C show a vending machine 1200 for vending various pods(e.g., pods 150) and depositing them into a built-in machine (e.g.,machine 600) to allow ice cream to be made and served into a bowl orcone. As such, vending machine 1200 can contain various types of pods,such as various types of ice creams, or any of the pods previouslydiscussed. One advantage is that vending machine 1200 can be used incommercial locations and be easily used by more than just one user.Additionally, since the pods 150 do not need to be refrigerated beforeuse, there is no need to refrigerate the vending machine 1200 whichlowers the cost to operate and manufacture.

As shown in FIG. 48A, vending machine 1200 contains nine pods (one ofwhich labeled pod 150) that are arranged in a rectangular or square gridbehind a viewing window 1204. Nine pods are shown but any number of podsor arrangements can be used. Each of the nine pods can contain a stackof pods behind the first pod so that when one pod is selected andremoved from vending machine 1200, a pod behind it will move forward.This is typically caused by gravity and/or a drive element such as aspring. For instance, pod 150 may have ten pods behind it so that themachine is stocked to require less frequent refills.

Vending machine 1200 includes an alphanumeric keypad 1206 that allows auser to make a pod selection. For example, to select pod 1222, the userwould enter “B” followed by “2” into the keypad 1206. Vending machine1200 also includes provisions to accept money 1208 by receiving cash andcoins using a cash receptacle and a coin receptacle, respectively.Vending machine 1200 can also accept credit card payments using a creditcard reader 1212, or any method to transfer money from a user to themachine, such as using ApplePay, or payments via an app or via theinternet. A similar server or network that is used in machine 100 canalso be implemented in the vending machine 1200. For example, asubscription service can be used to allow users access to a certainnumber of pods per month.

As mentioned above, vending machine 1200 includes the functionality ofthe cooling machine previously described (e.g., machine 600). Machine600 is shown in dashed lines to represent the fact that it is inside thevending machine 1200. Machine 600 includes an evaporator 1224 and adispensing receptacle or opening 1216. While the other features ofmachine 600 are not shown in FIGS. 48A-48C, it should be understood thatthe functionality of machine 600 is built-in to vending machine 1200 ina standalone package.

Vending machine 1200 includes a robotic arm 1214 (best seen in FIG. 48B)that can fetch a pod based on the user's selection and deposit it in theevaporator 1224. To achieve this, the robotic arm 1214 includes a basketor platform 1218 to receive a pod from a shelf and transport it safelyto the evaporator 1224. The robotic arm 1214 is configured to movehorizontally to move to the column of the selected pod. The basket 1218is configured to move vertically along the robotic arm 1214 to move tothe row of the selected pod. Both of these are typically driven by beltdrive systems coupled to rotary motors, but various actuation methodscan be used. Note that the robotic arm is shown in a retracted positionin FIGS. 48A and 48C.

For example, upon selecting pod 1222, the basket 1218 moves into thelocation “B2” as shown in FIG. 48B, and the pod 1222 is released intothe basket 1218. Once the pod is in the basket 1218, the pods behind thefirst pod can move to replace pod 1202, as previously mentioned.However, location “B2” is now empty in FIG. 48C.

Referring to FIG. 48C, the basket 1218 moves the pod 1222 to theevaporator 1224 and the process of making the ice cream can begin. Atthis point, the refrigeration system of vending machine 1200 cools theliquid ingredients in the pod 1222 to the desired temperature, typically17-26 degrees Fahrenheit. The vending machine 1200 inserts a driveshaftinto the pod 1222 to cause the mixing paddle of the pod 1222 to spin toprepare the ice cream and drive the ice cream downward. The vendingmachine 1200 can open the pod 1222 by shearing off the protrusion. Themixing paddle can then drive the ice cream out of the pod 1222 and intoa bowl, dish, or cone 1220. Once the process is complete, the pod 1222is removed and can be recycled. A receptacle within vending machine 1200can be used to store the used pods until they are recycled.

Alternatively, instead of using a robotic arm 1214, vending machine 1200can also permit manual selection by opening a window (substantiallysimilar to window 1204, except on a hinge, or sliding mechanism topermit it to swing or slide open) and allowing a user to reach in, graba selection, and place the pod in the evaporator manually.

FIG. 49 illustrates the comparison of ice crystal size typical ofstore-bought ice cream (e.g., Haagan-Dazs ice cream) versus the same icecream that is melted, packaged into a pod, and served using the machinesdescribed in this specification. Store-bought ice cream that is melted,packaged into a pod, and served using the machines described in thisspecification is considered “ColdSnap” ice cream. FIG. 49 illustratesthat the ColdSnap Haagen-Dazs ice cream 1502 has a 40% reduction in meanice crystal size compared to the store-bought Haagen-Dazs ice cream1504. Specifically, the ColdSnap Haagen-Dazs ice cream 1502 has a meanice crystal size of 19.2 μm compared to the store-bought Haagen-Dazs icecream 1504 with a mean ice crystal size of 31.9 μm. Additionally, thestandard deviation of the measured ice crystals in the ColdSnapHaagen-Dazs ice cream 1506 is much tighter than the standard deviationof the store-bought Haagen-Dazs ice cream 1508.

The machines described in this specification speed up impeller RPM sothat ice crystals do not have time to grow large which means that theice crystal size of the frozen ice cream is much smaller whichsignificantly improves texture and smoothness of the ice cream.

The ice crystal measurements shown in FIG. 49 were analyzed using alight microscope at 40× magnification housed in an insulated gloveboxsystem at a temperature of approximately −10° C. The samples weretransferred to the glovebox immediately after being frozen by the icecream machines described in this specification. The ice cream sampleswere placed on a microscope slide and a drop of 50% pentanol and 50%kerosene dispersing solution were added to aid in dispersing the icecrystals and to improve image quality. Images of the ice crystals wereobtained using optical light microscopy at 40× magnification.

During post-processing, the diameter of each ice crystal seen in animage was measured by tracing the boundary of the ice crystals shown inthe images. Measuring the boundary of the ice crystals was performedusing Microsoft Softonic Paintbrush for Mac with the assistance of anice crystal measurement macro in the Image Pro Plus software program.For each sample of ice cream analyzed, at least 300 ice crystals weremeasured per analysis to verify that a proper statistical average of icecrystal sizes was obtained.

FIGS. 50A-50E are images of ice crystals recorded using optical lightmicroscopy at 40× (40 times) magnification for various ice creams. FIG.50A includes three examples of the ice crystal images recorded formeasuring the ice crystal size for ColdSnap Sweet Cream 1 ice cream.Scale of the images are represented by the scale bar 1510 representing a100 μm length. Scale bars are shown in each of the three images of FIG.50A. Ice crystals are represented by the generally circular shapedobjects (e.g., objects 1512) in the images. There are many ice crystalsseen in the images. The mean diameter of the ice crystals is 21.7 μmwhich is smaller than the store-bought counterpart for this ice cream.

FIG. 50B includes three examples of the ice crystal images recorded formeasuring the ice crystal size for ColdSnap Sweet Cream 2 ice cream. Themean diameter of the ice crystals is 19.5 μm which is even smaller theice crystals seen in FIG. 50A and still less than the store-boughtcounterpart for this ice cream

FIG. 50C includes three examples of the ice crystal images recorded formeasuring the ice crystal size for ColdSnap Blueberry chobani ice cream.The mean diameter of the ice crystals is 21.2 μm but some ice crystalsare larger with a diameter of 76.9 μm. However, on average, the icecrystal size is still less than the store-bought counterpart for thisice cream.

FIG. 50D includes three examples of the ice crystal images recorded formeasuring the ice crystal size for ColdSnap Haagen-Dazs ice cream, whichwas also discussed with reference to FIG. 49. The mean diameter of theice crystals is 19.1 μm and the maximum ice crystal measured was 38.2μm, which is the lowest maximum ice crystal size of the ice crystalmeasurements shown in FIGS. 50A-50E. This mean ice crystal size issmaller than the store-bought counterpart for this ice cream which isshown in FIG. 50E.

FIG. 50E includes three examples of the ice crystal images recorded formeasuring the ice crystal size for store-bought Haagen-Dazs ice cream,which was also discussed with reference to FIG. 49. Notably, the meandiameter is 31.9 μm which is much larger than the ColdSnap Haagen-Dazsresult of 19.1 μm. All quantitative values (i.e., the mean ice crystaldiameter, the standard deviation, the minimum ice crystal diameter, andthe maximum ice crystal diameter) are larger for the store-bought icecream compared to the ColdSnap counterparts.

These results are a strong indication that the ice creams produced withthe machines described in this specification produce much smoother icecream that store-bought ice cream. The ice creams produced with themachines described in this specification were also 27% smaller in icecrystal size compared to the average ice cream crystal size of 25 μm.

Below is a table of the ice crystals size measurements shown in FIGS. 49and 50A-50E.

Mean Std. Dev. Min. Max. Sample/Data (μm) (μm) (μm) (μm) Cold Snap SweetCream 1 21.7 7.7 6.0 51.9 Cold Snap Sweet Cream 2 19.5 7.1 5.3 43.1ColdSnap Blueberry Chobani 21.2 13.2 6.5 76.9 ColdSnap HaagenDazs 19.16.24 6.7 38.3 Store-bought HaagenDazs 31.9 13.8 6.9 84.9

FIGS. 51A-51E are histograms of the ice crystal size measurements. FIG.51A is a histogram of the ColdSnap sweet cream 1 ice crystal sizedistribution which illustrates the tight standard deviation (or spread)of measurements about the mean ice crystal diameter of 21.7 μm.

FIG. 51B is a histogram of the ColdSnap sweet cream 2 ice crystal sizedistribution which illustrates the tight standard deviation ofmeasurements about the mean ice crystal diameter of 19.5 μm.

FIG. 51C is a histogram of the ColdSnap blueberry chobani ice crystalsize distribution which illustrates the tight standard deviation ofmeasurements about the mean ice crystal diameter of 19.5 μm.

FIG. 51D is a histogram of the ColdSnap Haagen-Dazs ice crystal sizedistribution which illustrates the tight standard deviation ofmeasurements about the mean ice crystal diameter of 19.1 μm.

FIG. 51E is a histogram of the store-bought Haagen-Dazs ice crystal sizedistribution which illustrates the wider standard deviation ofmeasurements about the mean ice crystal diameter of 31.9 μm. Not only isthe mean ice crystal diameter for the store-bought ice cream larger thanthe ColdSnap counterpart, but standard deviation is much greater.

As previously mentioned, the ice creams produced using the machinesdescribed in this specification have a much smaller ice crystal size onaverage and a much tighter standard deviation of ice crystal sizecompared to their store-bought counterparts. This is important becausethe ice cream machines described in this specification produce smootherice cream that does not require refrigeration or freezing prior to use.This means that the ice creams used in these machines do not need toinclude non-natural ingredients such as emulsifiers or stabilizers inthe ice cream. The ice creams used with these machines can be“clean-label” and contain simply milk, cream, sugar, and powdered milkand can be stored at room-temperature for up to 9 months in a sterilizedpod.

A number of systems and methods have been described. Nevertheless, itwill be understood that various modifications may be made withoutdeparting from the spirit and scope of this disclosure. For example,although the evaporators have been generally illustrated as being invertical orientation during use, some machines have evaporators that areoriented horizontally or an angle to gravity during use. Accordingly,other embodiments are within the scope of the following claims.

What is claimed is:
 1. A method of producing a single serving of cooledfood or drink, the method comprising: filling a plurality of pods withat least one ingredient for producing the single serving of the cooledfood or drink; sterilizing the plurality of pods such that the pluralityof pods become shelf stable; storing the plurality of shelf stable podsin a vending machine at room temperature; selecting a pod of theplurality of pods using a user interface of the vending machine;inserting the selected pod in a receptacle of an evaporator of thevending machine; and cooling the inserted pod using a refrigerationsystem of the vending machine while simultaneously churning at least oneingredient within the inserted pod using a mixing paddle to produce thesingle serving of the cooled food or drink.
 2. The method of claim 1,further comprising dispensing the single serving of the cooled food ordrink from the vending machine.
 3. The method of claim 2, furthercomprising storing the used pod in a receptacle of the vending machineafter the single serving of the cooled food or drink is dispensed fromthe vending machine.
 4. The method of claim 1, wherein the selected podis an aluminum pod and the mixing paddle is an aluminum mixing paddlethat is disposed within the aluminum pod.
 5. The method of claim 4,further comprising recycling the aluminum pod and the aluminum mixingpaddle.
 6. The method of claim 1, wherein sterilizing the plurality ofpods comprises subjecting the plurality of pods to at least one of aretort process or an aseptic filling process.
 7. The method of claim 1,wherein sterilizing the plurality of pods comprises simultaneouslyheating and mixing the at least one ingredient in each respective pod.8. The method of claim 7, wherein simultaneously heating and mixing theat least one ingredient in each respective pod comprises shaking eachrespective pod such that the at least one ingredient sloshes in eachrespective pod.
 9. The method of claim 1, wherein filling the pluralityof pods with the at least one ingredient comprises pressurizing aheadspace of the plurality of pods with a gas.
 10. The method of claim9, wherein filling the plurality of pods with the at least oneingredient comprises hermetically sealing the plurality of pods afterpressurizing the headspace and prior to sterilizing the plurality ofpods.
 11. The method of claim 1, wherein selecting the pod of theplurality of pods using the user interface causes the selected pod to beinserted in the receptacle of the evaporator of the vending machine. 12.The method of claim 1, wherein cooling the inserted pod comprisescooling the inserted pod from room temperature to a temperature between17-26 degrees Fahrenheit within 2 minutes.
 13. A method of producing asingle serving of a cooled dairy product, the method comprising: fillinga plurality of pods with at least one low acid ingredient for producingthe single serving of the cooled dairy product; sterilizing theplurality of pods such that the plurality of pods become shelf stable;storing the plurality of shelf stable pods in a vending machine at roomtemperature; and selecting and cooling one of the plurality of pods toproduce the single serving of the cooled food or drink.
 14. The methodof claim 13, wherein the at least one low acid ingredient has a pH ofgreater than or equal to 4.0.
 15. The method of claim 13, wherein the atleast one low acid ingredient is ice cream.
 16. The method of claim 13,wherein a sidewall of the plurality of pods is aluminum.
 17. The methodof claim 13, further comprising dispensing the single serving of thecooled food or drink from the vending machine.
 18. The method of claim13, further comprising storing the used pod in a receptacle of thevending machine after the single serving of the cooled dairy product isdispensed from the vending machine.
 19. The method of claim 13, whereinsterilizing the plurality of pods comprises subjecting the plurality ofpods to at least one of a retort process or an aseptic filling process.20. The method of claim 13, wherein cooling the inserted pod comprisescooling the inserted pod from room temperature to a temperature between17-26 degrees Fahrenheit within 2 minutes.
 21. A system for providing aplurality of single servings of cooled food or drink, the systemcomprising: a plurality of shelf stable pods; and a vending machineconfigured to store the plurality of shelf stable pods at roomtemperature, the vending machine comprising: a user interface operableto select a pod of the stored plurality of shelf stable pods; anevaporator defining a receptacle to receive the selected pod; arefrigeration system operable to cool at least one ingredient of theselected pod when the selected pod is received in the evaporator; and amixing motor operable to rotate a mixing paddle to chum the at least oneingredient to produce the single serving of the cooled food or drink.22. The system of claim 21, wherein the vending machine comprises adispenser operable to dispense the single serving of the cooled food ordrink.
 23. The system of claim 21, wherein the vending machine comprisesa storage receptacle for storing used pods.
 24. The system of claim 21,wherein each pod of the plurality of shelf stable pods is rendered shelfstable by subjecting each pod to a sterilization process.
 25. The systemof claim 24, wherein the sterilization process is at least one of aretort process or an aseptic filling process.
 26. The system of claim21, wherein the selected pod comprises the mixing paddle.
 27. The systemof claim 13, wherein each pod of the plurality of shelf stable podscomprises a respective mixing paddle.
 28. The system of claim 27,wherein a sidewall of the plurality of pods is aluminum and eachrespective mixing paddle is aluminum.
 29. The system of claim 21,wherein the refrigeration system is operable to cool the at least oneingredient of the selected pod from the room temperature to atemperature between 17-26 degrees Fahrenheit within 2 minutes.
 30. Thesystem of claim 21, wherein the plurality of shelf stable pods areself-stable for at least 6 months.